Shippable Battery Module With Disconnecting Backplane
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Solution Overview
Problem
High power density batteries, such as lithium ion batteries, pose a risk of combustion during shipping due to potential short circuits, necessitating electrical isolation during transport to prevent fires, and existing methods require on-site electrical connections using jumper wires, which can lead to improper connections.
Innovation Solution
A battery module design featuring a cabinet with a backplane and electrical connections that can disconnect from the battery during transport, using a mechanism like locking pins or contactors to ensure electrical isolation, and reconnect upon installation, utilizing blind mate connectors for secure and tool-free connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are electrically connected to the backplane during transport, then the battery module is ready for operation, but the risk of combustion increases due to potential short circuits
Solution Approach 1:
The electrical connection system is segmented into separate components: the backplane with its electrical contacts and the battery terminals. A mechanical locking mechanism segments the connection state into distinct locked (connected) and unlocked (disconnected) positions, allowing the system to be transported in a disconnected state for safety and locked at the installation site for operational readiness
Solution Approach 2:
The backplane and electrical connection components are pre-installed in the cabinet during manufacturing, but the actual electrical connection is deferred until the installation site. The locking mechanism is pre-configured to allow easy engagement and disengagement, enabling preliminary preparation without premature electrical connection that would create combustion risk during transport
2Object-affected harmful factors
If batteries are electrically isolated during transport, then combustion risk is reduced, but additional connection steps are required at the installation site
Solution Approach 1:
The electrical connection function and mechanical locking function are merged into a single integrated mechanism. When the locking mechanism engages, it simultaneously secures the battery in position and establishes electrical contact between the battery terminals and the backplane, eliminating the need for separate connection steps and reducing installation complexity
Solution Approach 2:
The locking mechanism is designed to automatically establish electrical connections when engaged, without requiring additional manual wiring or connection steps. The mechanical action of locking the battery into place self-service the electrical connection function, simplifying the installation process while maintaining safety during transport
3Adaptability or versatility
If manual electrical connections are made using jumper wires, then flexibility in installation is achieved, but improper connections may occur
Solution Approach 1:
The locking mechanism serves as an intermediary device that mediates between the battery and the backplane. It provides predefined, precise alignment features that guide the battery into the correct position, ensuring accurate electrical connections without requiring manual wiring skills or judgment, thus eliminating improper connections while maintaining installation flexibility
Data Source
AI summary
A method of transporting a battery module includes transporting the battery module containing at least one battery and a backplane disposed in a cabinet to an operating site such that the at least one battery is electrically isolated from the backplane during the transporting, installing the battery module at the operating site, and electrically connecting the at least one battery to the backplane after the transporting.