3D Battery Pack Structure for Lightweight Cell Integration
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Solution Overview
Problem
Existing vehicular battery packs are heavy and bulky due to the use of metal containers for individual cells, which limits space optimization and performance in electric vehicles, as they are typically assembled in standard dimensions and do not conform to the sinuous profiles of car bodies.
Innovation Solution
A vehicular battery pack with a three-dimensional substrate that supports primary units without individual metal containers, using a prismatic structure with seats for the cells and integrated closure assemblies, allowing for customized shapes and improved space utilization, and employing additive manufacturing for lightness and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual metal containers are used for each battery cell, then cell protection and structural integrity are improved, but battery pack weight and dimensions increase significantly
Solution Approach 1:
The patent merges the individual cell containers into a single common housing structure that accommodates multiple cells. Instead of each cell having its own separate metal container, all cells are housed within one shared container with individual seats, eliminating redundant materials and reducing overall weight while maintaining protection and structural integrity.
2Ease of manufacture
If standard-dimensional modules are assembled in series, then manufacturing simplicity is improved, but space utilization and optimization are worsened due to inability to follow sinuous car body profiles
Solution Approach 1:
The battery pack is segmented into multiple individual cell seats arranged within the common housing, allowing each cell to be positioned independently. This segmentation enables the battery pack to conform to complex vehicle body profiles while maintaining standardized cell components, thus optimizing space utilization without sacrificing manufacturing simplicity.
Solution Approach 2:
The patent transitions from rigid series assembly to a three-dimensional arrangement of cells within the common housing. Cells can be positioned in multiple dimensions and orientations to match the sinuous profiles of car bodies, maximizing space utilization while maintaining ease of manufacture through modular cell placement.
3Reliability
If individual metal containers are used for each cell, then cell containment is improved, but the number of inactive heavy materials increases, affecting vehicle performance
Solution Approach 1:
The patent combines multiple individual cell containers into a single common housing structure, eliminating redundant metal materials. The common housing provides containment for all cells while using significantly less inactive material than individual containers would require, thus improving vehicle performance by reducing weight.
4Ease of manufacture
If standard battery modules are used, then assembly process is simplified, but customization to fit specific vehicle profiles is limited
Solution Approach 1:
The battery pack uses segmented individual cell seats within a common housing, allowing customization of cell positions and arrangements to match specific vehicle profiles. This segmentation maintains assembly simplicity through modular components while enabling adaptability to different vehicle configurations.
Data Source
AI summary
A vehicular battery pack comprising a three-dimensional substrate arranged within the housing and provided with a plurality of seats, which extend on the inside of the substrate; a plurality of active primary units; wherein each primary unit is entirely inserted in a respective seat; wherein each seat has a shape that is complementary to the one of each primary unit; the battery pack further comprising a first closure assembly, which closes said plurality of primary units inside the respective seats; wherein the closure assembly comprises a plurality of first closure elements, which are electrically conductive and are each arranged in the area of a respective opening; wherein the first terminal is electrically in contact with the respective first closure element of the respective seat.