Flexible Battery Cell Carrier Structure for Swelling Accommodation
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Solution Overview
Problem
Existing battery packs face challenges in achieving high energy density and low weight, particularly in non-stationary applications like vehicles, where battery swelling and external forces require flexible and efficient structural solutions.
Innovation Solution
A carrier unit for battery modules is designed to be at least partially flexible, featuring a bottom portion and side portions that can deform elastically or plastically to accommodate battery swelling and external forces, while maintaining a lightweight and compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the carrier unit is made rigid to provide structural support for battery cells, then the mechanical strength is improved, but the ability to accommodate battery swelling is reduced
Solution Approach 1:
The carrier unit is designed with flexible zones that allow dynamic deformation to accommodate battery swelling while maintaining structural support. The flexibility is achieved through specific geometric configurations of the side portions and bottom portion that can elastically deform under swelling forces and return to their original shape, providing both strength and adaptability.
Solution Approach 2:
The carrier unit incorporates flexible side portions and bottom portions that act as flexible shells. These thin-walled structures provide the necessary mechanical strength to carry battery cells while simultaneously allowing deformation to accommodate swelling, resolving the contradiction between rigidity and flexibility.
2Weight of moving object
If the carrier unit is made lightweight to achieve high energy density, then the weight is reduced, but the structural strength may be compromised
Solution Approach 1:
The carrier unit utilizes thin-walled flexible structures that provide adequate structural strength while minimizing weight. The flexible side portions and bottom portion are designed with optimized thickness and geometry to carry battery cell loads without requiring heavy materials, thus achieving high energy density.
Solution Approach 2:
The carrier unit is constructed from composite materials that combine high strength-to-weight ratio properties. By using materials such as aluminum alloys or fiber-reinforced polymers, the structure achieves both lightweight characteristics and sufficient mechanical strength to support battery cells.
3Volume of moving object
If the side portions are made tall to provide adequate accommodation space for battery cells, then the volume is increased, but the structural stability is reduced
Solution Approach 1:
The side portions are designed with dynamic flexibility rather than rigid height. The flexible side portions can deform to accommodate battery swelling while maintaining structural stability through their elastic properties. This eliminates the need for excessively tall rigid structures, optimizing both volume and stability.
Solution Approach 2:
The side portions incorporate curved or rounded geometries rather than sharp angles, which distribute stresses more evenly and improve structural stability. The curved profiles provide adequate accommodation space while enhancing the overall structural integrity of the carrier unit.
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 flexible carrier unit effectively manages forces from battery swelling and external sources, allowing for a high energy density and low weight battery pack design that is both durable and efficient.
Implementation Method 1
The flexible carrier unit effectively manages forces from battery swelling and external sources, allowing for a high energy density and low weight battery pack design that is both durable and efficient
Implementation Method 2
the carrier unit comprises two side portions configured to accommodate the at least one row of battery cells in a space formed between the two side portions. The carrier unit may be at least partially flexible
Data Source
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AI summary
The disclosure relates to carrier unit (10) for a battery module (30), the carrier unit (10) comprising a bottom portion (11) configured to carry at least one row (20) of battery cells (21); and two side portions (14) configured to accommodate the at least one row (20) of battery cells (21) in a space formed between the two side portions (14); the carrier unit (10) being at least partially flexible.