Replaceable EV Battery Coupling With Joint Coil Core Alignment
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Solution Overview
Problem
Conventional battery systems in electric vehicles suffer from high energy transmission losses, mechanical wear, and unreliable electrical coupling due to inductive energy transfer and plug contacts, which are prone to damage and failure.
Innovation Solution
A battery system with a joint coil core formed by aligning and mechanically coupling first and second coil cores, using converters to convert DC to AC for efficient inductive energy transfer, and protective layers to prevent corrosion, ensuring robust and reliable electrical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If inductive energy transmission is used for battery exchange, then energy can be transferred wirelessly, but energy losses are high and position control is difficult
Solution Approach 1:
The patent replaces the inductive coupling mechanism with a direct mechanical electrical connection system. The battery and vehicle each have electrical plug contacts that connect directly when the battery is installed, eliminating the inductive energy transmission path and its associated losses. This mechanical substitution resolves the energy loss issue while maintaining wireless-like convenience for battery exchange.
Solution Approach 2:
The patent introduces a mechanical coupling element as an intermediary between the battery and vehicle electrical systems. This coupling element includes electrical plug contacts that provide both mechanical support and electrical connection, serving as a mediator that eliminates the need for inductive coupling while ensuring reliable energy and signal transmission.
2Reliability
If electrical plug contacts are used for coupling, then electrical connection can be established, but the contacts are easily damaged by tilting during battery installation
Solution Approach 1:
The patent applies beforehand cushioning by designing the electrical plug contacts with protective features that prevent damage before it can occur. The coupling element includes alignment features and protective structures that cushion against tilting forces during battery installation, preventing contact damage while maintaining easy installation procedures.
Solution Approach 2:
The patent employs flexible protective structures around the electrical plug contacts that can deform to accommodate tilting during installation while maintaining electrical connection. These flexible elements absorb misalignment forces and protect the fragile contacts from damage, resolving the contradiction between reliability and ease of operation.
3Power
If conventional batteries are designed for sufficient power, then high voltage is achieved, but the batteries become large and heavy
Solution Approach 1:
The patent applies segmentation by making the battery exchangeable as a separate module from the vehicle electrical system. The battery can be optimized for power density and weight independently, while the vehicle retains its electrical infrastructure. This allows using lighter, high-power-density batteries without compromising overall system power capability, as batteries can be swapped rather than being permanently integrated.
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
The system achieves reduced energy losses, improved durability, and secure electrical connections, allowing for efficient energy transfer and easy battery exchange without damaging plug contacts.
Implementation Method 1
The battery has a first converter for converting a direct current of the battery into an alternating current
Implementation Method 2
a first coil for producing an alternating magnetic field for transmitting energy to the motor vehicle
Implementation Method 3
a second coil for receiving energy from the first coil
Data Source
AI summary
The invention relates to a battery system (1) for a motor vehicle (2), comprising: a battery (3) for providing electrical energy for the motor vehicle (2), the battery having a first converter (4) for converting a direct current of the battery (3) into an alternating current and a first coil (5) for producing an alternating magnetic field for transmitting energy to the motor vehicle (2); and a second coil (7) for receiving energy from the first coil (5), which second coil can be arranged on the motor vehicle (2) and can be electrically coupled to a vehicle electrical system (6) of the motor vehicle (2). The first coil (5) is wound around a first coil core (8) and the second coil (7) is wound around a second coil core (9), the first coil core (8) having a first contact region (10) for mechanically coupling to a second contact region (11) of the second coil core (9) in order to produce a joint coil core. The invention further relates to a motor vehicle (2).