Removable Battery Component Carrier for Modular Submodule Replacement
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Solution Overview
Problem
Existing battery systems require the disassembly of entire modules for replacing defective submodules, which is cumbersome and costly due to the mechanical integration of high-capacity, large, and heavy modules.
Innovation Solution
A removable battery component carrier system that allows individual detachment and reconnection of battery submodules, featuring a bottom plate, side walls, end plates, and a cell cover with integrated cooling channels, along with a cell connection and sensing unit for electrical and thermal management, enabling modular assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery modules are mechanically integrated with common current collector structure and battery management system, then mechanical integrity and structural stability are improved, but replacement of defective submodules requires disassembly of entire module increasing repair complexity and time
Solution Approach 1:
The battery module is segmented into independent submodule units, each with its own current collector and management system. This allows individual submodules to be removed and replaced without disassembling the entire battery module, resolving the contradiction between maintaining mechanical integrity and enabling easy repair.
Solution Approach 2:
The current collector structure and battery management system are extracted from being common shared components and assigned to individual submodules. This extraction enables each submodule to be independently handled, replaced, and repaired without affecting other submodules, while still maintaining overall mechanical stability through standardized mounting interfaces.
2Power
If high-capacity battery modules are designed with fixed mechanical integration, then energy density and power output are improved, but weight and size increase making storage and handling difficult
Solution Approach 1:
The high-capacity battery module is divided into smaller submodule segments. Each submodule maintains sufficient energy density through optimized cell arrangements, while the modular structure reduces the weight and size burden during storage and handling. Multiple lighter submodules can be distributed and stored more easily than a single heavy integrated module.
3Reliability
If battery cells are confined in individual casings arranged into battery module, then mechanical protection and thermal management are improved, but installation space requirement increases
Solution Approach 1:
Multiple individual cell casings are merged into a shared submodule enclosure structure. This merging maintains the mechanical protection benefits of individual casings while reducing the total installation space by eliminating redundant casing walls and shared structural elements between adjacent cells.
Solution Approach 2:
The submodule casing structure serves multiple functions simultaneously: it provides mechanical protection for battery cells, acts as a thermal management conduit, and serves as the mounting interface for the current collector system. This multi-functionality reduces the need for separate protective structures, thereby reducing installation space.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates easy assembly, disassembly, and repair of battery systems, reducing manufacturing costs by allowing separate replacement of submodules and forming an overall cooling channel for efficient heat dissipation.
Implementation Method 1
a cooling fin disposed between the plurality of battery cells
Implementation Method 2
forming an overall cooling channel running through the whole battery system
Data Source
AI summary
A removable battery component carrier (30,60) for accommodating a battery submodule (40,64) and configured to be mechanically and electrically connected to other removable battery component carriers (30,60) and/or to a carrier frame is provided. The removable battery component carrier (30,60) comprises a bottom plate (32,62), a pair of side walls (31) extending upward from the bottom plate (32,62) along two longitudinal edges of the bottom plate (32,62), a pair of end plates (33) extending upwards from the bottom plate (32,62) along two transversal edges of the bottom plate (32,62). The end plates (33) are mechanically coupled to the side walls (31) and/or to the bottom plate (32,62) to fix battery cells (1,1′) together. A cell cover (34,66) extends parallel to the bottom plate (32,62) so that the cell cover, the bottom plate, the side walls, and the end plates form an accommodating space for the battery submodule (40,64).