Swappable Vehicle Battery Base Unit for Lead-Acid Compatibility
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Solution Overview
Problem
Lead-acid batteries used in vehicles and equipment suffer from unpredictable failure, are cumbersome to replace, and have environmental drawbacks, while alternative chemistries like lithium-ion face compatibility and cost issues.
Innovation Solution
A modular battery system comprising a base unit and swappable lithium or compatible batteries, designed to fit existing lead-acid battery spaces, with quick connectors and intelligent management, allowing easy replacement and charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lead-acid batteries are used, then compatibility with existing vehicle charging systems is maintained, but weight and size increase
Solution Approach 1:
The battery system is divided into a base unit and removable battery modules. The base unit contains the charging system interface and control electronics, while the battery modules can be independently swapped. This segmentation allows the heavy lead-acid battery to be replaced with lighter modules while maintaining compatibility through the standardized base unit interface.
Solution Approach 2:
The base unit is designed with universal interfaces that can accommodate different battery module types and chemistries. The charging system in the base unit can work with various battery configurations, allowing the system to maintain compatibility with existing vehicle charging systems while enabling weight reduction through modular replacement.
2Ease of manufacture
If lead-acid batteries are used, then cost is reduced, but cycle life and discharge ability are limited
Solution Approach 1:
The system allows changing the chemical parameters of the battery by swapping modules with different chemistries (e.g., lithium-ion, nickel-metal hydride). This enables selection of battery chemistry optimized for cycle life and discharge ability while using the same base unit, effectively decoupling the cost interface from the performance characteristics.
Solution Approach 2:
The battery system transitions from a static lead-acid configuration to a dynamic modular system where battery modules can be swapped based on performance needs. This allows the system to adapt to different operational requirements and extend overall system lifecycle by replacing only the battery modules rather than the entire battery system.
3Ease of manufacture
If lead-acid batteries are used, then initial cost is reduced, but environmental impact increases
Solution Approach 1:
The modular battery system facilitates easier recovery and recycling of battery materials. By using standardized modules with uniform connection interfaces, the system enables efficient collection and processing of battery modules at end-of-life, improving the economic viability of recycling programs and reducing environmental impact through material recovery.
4Device complexity
If lead-acid batteries are used, then simplicity is maintained, but flexibility and orientation options are reduced
Solution Approach 1:
The battery system is segmented into a fixed base unit and removable modules. The base unit contains the complex charging interface and control systems, while the modules are simplified for easy removal and reinstallation. This segmentation maintains operational simplicity for the user while enabling flexibility in module configuration and orientation.
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
Enables quick, safe, and cost-effective swapping of batteries, maintaining system functionality without downtime, and addressing environmental concerns.
Implementation Method 1
The battery comprises a number of battery cells
Data Source
AI summary
Examples relate to vehicle battery systems comprising a base unit connectable to a vehicle's electrical system, a removable modular replaceable battery, and a secondary battery within the base unit. The base unit is configured to interchangeably use modular replaceable batteries of different chemistries. Control circuits optimize charging and discharging parameters based on battery chemistries. The secondary battery provides power when the modular battery is removed. The system includes thermal management, compatibility with lead-acid charging systems, and mobile base unit functionality. The modular battery can power external devices and can foreseeably store energy up to and beyond 1 kWh. The system operates at various voltages suitable for different vehicle types.