EV Battery Cross-Beam Layout for Lateral Impact and Cell Packing
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Solution Overview
Problem
The compactness and energy density of electric vehicle batteries are compromised due to the space required for electrical connections spanning crosspieces in the housing, which also affects their ability to withstand lateral impacts.
Innovation Solution
A battery design featuring a housing with crosspieces and assemblies arranged in a longitudinal direction, utilizing angles to transmit transverse forces and secure electrochemical cells, allowing for efficient packing and improved impact resistance without compromising energy storage volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrical connections span the crosspieces in the housing, then the battery structure can support lateral impacts, but space is left above the electrochemical cells reducing compactness and energy density
Solution Approach 1:
The patent relocates electrical connectors from spanning across the top of crosspieces to being positioned at the lateral edges of the housing. This dimensional repositioning allows connections to be made at the periphery rather than requiring overhead space, thereby eliminating the empty space above electrochemical cells while maintaining structural integrity for impact resistance
Solution Approach 2:
The patent introduces angle pieces as intermediary structural elements that connect crosspieces to the housing at the lateral edges. These angle pieces serve as mediators that enable electrical connections to be routed through the edge structure rather than spanning across the top, thus resolving the conflict between maintaining impact resistance and maximizing space utilization
2Strength
If crosspieces are used to withstand lateral shocks, then the housing gains structural strength, but space is consumed by the crosspiece structure reducing available volume for cells
Solution Approach 1:
The patent applies crosspieces and angle pieces only at specific locations where structural strength is needed - namely at the lateral edges and at intervals along the housing - rather than uniformly throughout. This localized application maintains necessary shock resistance while minimizing the volume consumed by the support structure, allowing maximum space for electrochemical cells
Data Source
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AI summary
Battery for an electric or hybrid vehicle, comprising: - a casing (12) defining a housing (14) extending in a longitudinal direction (X) and in a transverse direction (Y), the casing comprising a first lateral edge (18), - a plurality of transverse cross members (16), - a plurality of assemblies comprising electrochemical cells (24), the cross members and the assemblies being arranged successively in the housing in the longitudinal direction, - a plurality of angle brackets (28) for transmitting transverse forces between the cross members and the casing, at least some of the angle brackets comprising a first portion (92) extending perpendicularly to the transverse direction and fixed to a transverse end of at least some of the cross members, and a second portion (94) extending transversely from the first portion and being fixed to the first lateral edge, the assemblies, the first portion,and the first lateral edge defining at least partially a housing (96) extending longitudinally.