Scalable Battery Module With 3D Connectors

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Solution Overview

Problem

Existing battery modules are inflexible and cannot accommodate different battery sizes and shapes due to their fixed dimensions, leading to inefficiencies in cooling and manufacturing, and require complex connections and heavy metal components.

Innovation Solution

A scalable battery module system comprising submodules connected by connectors that allow expansion in three dimensions, eliminating the need for a cold plate and reducing manufacturing complexity, with built-in cooling chambers and plug-in features for thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fixed size batteries are used in a battery module, then the module can be designed to fit a specific vehicle space, but the module cannot be adapted to fit other vehicles with different spaces

Engineering Contradiction:

Improveadaptability to different vehicle spacesVSAvoidbattery module design complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The battery module is divided into multiple submodules (first submodule, second submodule, third submodule) that can be independently configured. Each submodule contains battery cells arranged in a specific pattern, and these submodules can be combined in different configurations to create battery modules of various sizes and shapes, enabling adaptation to different vehicle spaces without redesigning the entire module.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a vertical dimension (height) as a third degree of freedom for scaling, in addition to length and width. By arranging submodules in stacked configurations vertically, the battery module can achieve three-dimensional scalability, allowing it to fit various vehicle spaces by adjusting dimensions in all three spatial dimensions rather than being limited to two-dimensional scaling.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If complex connections and heavy metal components are used, then structural strength is improved, but manufacturing costs and device weight increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity and cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connectors are designed with multi-functionality, serving both mechanical connection and electrical connection purposes simultaneously. The same connector structure provides both structural support (mechanical strength) and electrical pathways for current flow, eliminating the need for separate metal components for each function and simplifying the overall assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent extracts and eliminates the cold plate component from the traditional battery module design. Instead of using a separate cold plate for thermal management, the cooling function is integrated directly into the submodule structure through cooling channels formed within the submodule housing, reducing the number of heavy metal components needed.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If traditional battery module designs are used, then manufacturing is simplified, but cooling efficiency is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcooling efficiency

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The cooling function is merged with the structural housing of the submodules. The cooling channels are formed as integral parts of the submodule housing structure rather than being separate components, combining thermal management functionality with structural support in a single element that can be manufactured using standard injection molding processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The submodule housing acts as an intermediary structure that simultaneously provides mechanical support and thermal management. The housing material and design serve as a mediator between the battery cells (heat source) and the external cooling system, with cooling channels embedded within the housing to efficiently conduct heat away from the cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11342620B2Battery module scalable in three dimensions

Publication Date: 2022.05.24 CHONGQING JINKANG POWERTRAIN NEW ENERGY CO LTD

AI summary

Provided is a scalable battery module. In once example embodiment, the module includes a plurality of submodules. Each plurality of submodules is configured to hold one or more cell batteries. The module further includes one or more of a first connector, a second connector, or a third connector. The first connector may secure an alignment of two or more adjacent submodules of the plurality of submodules along a first dimensional axis by using at least one of two slots and two projections of the first connector. The second connector secures the alignment of two adjacent submodules of the plurality of submodules along a second dimensional axis by using at least two further slots of the second connector. The third connector secures the alignment of two adjacent submodules of the plurality of submodules along a third dimensional axis by using at least two further projections of the third connector.