Structural Battery Cell Layout for Frame Rail Load Transfer
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Solution Overview
Problem
Conventional traction battery packs in electrified vehicles lack an efficient mechanism to transfer loads between opposing frame rails, which can affect the distribution and management of forces within the vehicle.
Innovation Solution
The battery cells are arranged and secured between the first and second frame rails of an electrified vehicle, with cylindrical cells having metal or metal alloy outer cases that are directly secured or welded to each other, forming a connected network that spans across the frame rails, allowing load transfer between the rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional battery packs are used without direct cell-to-cell securing, then installation is simpler, but load transfer between frame rails is inefficient
Solution Approach 1:
The patent merges the battery cell holders with the frame rails, creating an integrated structure where the holders are formed as part of the frame rails themselves. This integration enables direct load transfer from one frame rail to another through the battery cells while eliminating separate mounting components, thus improving force transfer capability without proportionally increasing device complexity
Solution Approach 2:
The battery cells serve multiple functions: they provide electrical energy storage and simultaneously act as structural load-bearing elements that transfer forces between frame rails. This multi-functionality allows the same component to address both energy storage requirements and structural load transfer needs, improving force transfer capability while avoiding additional dedicated load transfer structures
2Reliability
If battery cells are directly secured to each other, then load transfer efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The battery pack is segmented into modular units with battery cells arranged in discrete groups held by separate holders. Each holder secures a specific group of cells, allowing for standardized, repeatable assembly processes. This segmentation enables the complex direct-securing arrangement to be manufactured efficiently through modular assembly rather than requiring complex integrated structures
Solution Approach 2:
The battery cells are pre-assembled into groups and secured to holders before being installed in the final pack configuration. This preliminary grouping and securing simplifies the overall assembly process by reducing the number of individual securing operations needed during final installation, thereby improving structural integrity while maintaining ease of manufacture
3Strength
If frame cross-members overlap with battery cells, then structural support is enhanced, but space utilization decreases
Solution Approach 1:
The patent merges the function of frame cross-members with the battery cell holders, where the holders are integrated into the frame structure. This integration provides structural support through the battery cell arrangement itself, eliminating the need for separate cross-members that would overlap with battery cells, thereby maintaining strength while maximizing battery pack space
Data Source
AI summary
A traction battery assembly includes, among other things, battery cells configured to be positioned between a first frame rail of an electrified vehicle and an opposite, second frame rail of the electrified vehicle. The battery cells are arranged to transfer a load from the first frame rail to the second frame rail. A method of securing battery cells includes, among other things, positioning battery cells between a first frame of an electrified vehicle and an opposite, second frame rail of the electrified vehicle. The battery cells are positioned to transfer a load from the first frame rail to the second frame rail.