Exchangeable Split Profile Battery Cell Carrier for Modular Maintenance
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Solution Overview
Problem
Existing battery pack systems require dismounting of the entire system for replacing defective parts, leading to burdensome procedures and difficulties in thermal management, especially in high-capacity, expensive, and heavy battery systems, where thermal deviations can affect performance and lifespan.
Innovation Solution
A frame design for battery packs with two sub-beams that allow for easy exchange of battery cell stacks, incorporating cooling means within the beams and a rigid connection to reduce thermal propagation, enabling flexible configuration and maintenance without disassembling the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire battery system is disassembled for replacing defective parts, then complete access to all components is achieved, but the maintenance procedure becomes burdensome and time-consuming
Solution Approach 1:
The battery system is segmented into modular battery cell stacks that can be independently removed and replaced. Each stack is a self-contained unit with standardized mounting interfaces, allowing defective stacks to be exchanged without disassembling the entire battery system. This modular architecture directly enables quick replacement of only the faulty component while leaving other stacks intact.
2Productivity
If battery cell stacks are closely arranged to increase energy density, then space utilization is improved, but thermal propagation risk between stacks increases
Solution Approach 1:
Thermal insulation material is introduced as an intermediary substance between adjacent battery cell stacks. This mediator layer physically separates the stacks thermally while maintaining their close spatial arrangement for high energy density. The insulation material blocks heat transfer pathways, preventing thermal propagation from one stack to another even when stacks are densely packed.
3Temperature
If cooling means are integrated within the beams to improve thermal management, then heat dissipation efficiency is enhanced, but the structural complexity of the frame increases
Solution Approach 1:
The cooling function is merged with the structural beams by integrating cooling channels directly into the beam architecture. The beams serve dual purposes: providing mechanical support for the battery stacks and acting as heat dissipation pathways. This combination eliminates the need for separate cooling structures, reducing overall system complexity while maintaining effective thermal management.
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 frame design enhances safety and reduces manufacturing costs by allowing for cost-effective production, easy maintenance, and improved thermal management, enabling efficient heat dissipation and reducing the risk of thermal propagation between battery cell stacks.
Implementation Method 1
incorporating cooling means within the beams and a rigid connection to reduce thermal propagation
Implementation Method 2
enabling efficient heat dissipation
Data Source
AI summary
A frame for a battery pack includes: a first end beam; a second end beam; and one or more intermediate beams between the first end beam and the second end beam. Each of the beams is orientated along a first direction that is perpendicular to a virtual plane, and includes: a first plate having a first side, and a second side opposite to the first side of the first plate; a second plate having a first side, and a second side opposite to the first side of the second plate; and a coupling means slidably coupling the second side of the first plate to the second side of the second plate to inhibit any displacement of the first plate relative to the second plate, except for a shifting of the first plate relative to the second plate in or against the first direction.