Riveted Battery Module Design for Space-Efficient Sealed Lead Acid Storage
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Solution Overview
Problem
Existing systems for storing and transporting sealed lead acid batteries are inefficient in terms of space usage and require a more convenient and economical solution, especially for telecommunication systems with high power requirements.
Innovation Solution
A modular system comprising custom-formed bent steel components, including top and bottom trays with slits and side walls with flanges and apertures, allowing for easy assembly and stacking of battery modules using fasteners like rivets or bolts, which can be assembled on-site or shipped pre-assembled, ensuring secure containment and air circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional racks or cabinets are used to store batteries, then the batteries are securely contained, but the space occupied is significant and inefficient
Solution Approach 1:
The battery storage system is divided into modular units that can be stacked and configured in different arrangements. Each module contains trays for holding batteries and can be independently assembled, allowing flexible space utilization while maintaining secure containment through standardized structural components
Solution Approach 2:
The modular design allows smaller modules to be nested within or stacked upon larger structures, maximizing space utilization. The trays and modules are designed to fit together in a nested configuration that minimizes wasted space while maintaining structural integrity for secure battery containment
2Ease of manufacture
If custom-formed bent steel components with slits and flanges are used, then easy assembly and stacking is achieved, but manufacturing complexity increases
Solution Approach 1:
The structure is segmented into standardized components (trays with slits, side walls with flanges, end walls) that can be manufactured separately using cold-forming techniques and then assembled together. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly process through modular construction
Solution Approach 2:
The steel components are formed using cold-forming processes that change the physical parameters of the material (shape, curvature) without heat treatment. The slits and flanges are created through controlled deformation processes that maintain material properties while achieving the desired geometric configurations for easy assembly
3Strength
If multiple fastening devices like rivets and bolts are used to attach components, then secure attachment is achieved, but assembly time and complexity increase
Solution Approach 1:
The fastening system is segmented into different types of apertures and corresponding fasteners used in specific locations based on structural requirements. Critical joints use stronger fastening methods while less critical connections use simpler fasteners, optimizing both strength and assembly efficiency across the entire structure
Solution Approach 2:
Multiple types of apertures are designed to accommodate different fastening devices (rivets, bolts, screws), allowing the same aperture design to serve multiple fastening functions. This universal aperture design enables flexibility in assembly methods while maintaining consistent attachment strength across different connection points
4Temperature
If slots are added to trays for air circulation, then cooling is improved, but structural integrity may be compromised
Solution Approach 1:
The trays are designed with slots in specific locations where air circulation is most needed for cooling, while maintaining solid structural sections in areas requiring maximum strength. The slot placement and sizing are optimized to provide adequate airflow paths without creating weak points that would compromise the overall structural integrity of the tray
Data Source
AI summary
A modular system for mounting batteries that includes one or more modules mounted on a base. Each of the modules includes a top tray and a bottom tray and two side walls. The first end of each tray has a wall extending from the surface and the opposing sides have a section that is inserted into slots in the side walls. The side walls have a flanged edge on all four sides. A plurality of apertures in the top tray, the bottom tray, the tray walls and the flanges of the side walls are aligned and fastening devices are used to secure the trays to the side walls and to attach adjacent modules to form the modular system.