Shared Battery Housing With Cross Separators to Prevent Cell Contact

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Solution Overview

Problem

Existing battery module structures fail to meet the requirements of lightweight, low cost, and high-energy density due to the use of numerous structural components, leading to potential short circuits and safety hazards when cells come into contact.

Innovation Solution

A battery design featuring a housing with at least two electrode core sets connected in series, separated by a first and second separator arranged perpendicular to each other, forming a gap to prevent contact and enhance support, while reducing weight and cost through shared housing and reduced external components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If multiple cells are arranged side by side to increase capacity, then the overall capacity of the battery pack is improved, but the total weight of the battery pack increases

Engineering Contradiction:

Improvebattery capacityVSAvoidbattery pack weight

Core Design Contradiction:

Quantity of substanceVSWeight of stationary object

Solution Approach 1:

The patent merges multiple cells into a shared housing structure where multiple electrode core sets are arranged within a single common housing. This consolidation eliminates the need for separate housings for each cell, reducing the overall structural weight while maintaining the required battery capacity through multiple electrode assemblies.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The shared housing structure serves multiple functions: it provides mechanical support for multiple electrode core sets, acts as a common protective enclosure, and eliminates the need for separate housing components for each cell. This multi-functionality reduces the total number of parts and associated weight while maintaining structural integrity and safety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If numerous structural components are used in battery module structures, then the structural strength and safety are improved, but the weight and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidbattery pack weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent combines multiple structural support functions into a single shared housing structure. Instead of using separate support components for each cell, the housing integrates support for multiple electrode core sets, reducing the total number of structural parts while maintaining adequate mechanical strength through optimized housing design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates redundant structural components that would be present in traditional multi-cell configurations. By removing unnecessary intermediate support structures and using the housing to provide direct support, the design reduces weight and complexity while maintaining structural integrity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If numerous structural components are used in battery module structures, then the structural support is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural supportVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges multiple structural support functions into a single shared housing structure, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation simplifies the supply chain and manufacturing process while maintaining adequate structural support through optimized housing design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent segments the battery pack into modular electrode core sets that can be independently manufactured and then assembled within the shared housing. This modular approach allows for standardized production of core components while simplifying the final assembly process, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #1Segmentation

4Device complexity

If cells are arranged without adequate separation, then the structural complexity is reduced, but the risk of short circuit and safety hazards increases

Engineering Contradiction:

Improvestructural complexityVSAvoidsafety reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces separator structures as intermediary elements between adjacent electrode core sets within the shared housing. These separators act as physical barriers that prevent direct contact between cells, eliminating short circuit risks while maintaining a relatively simple overall structure. The separators are integrated into the housing design to minimize added complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4053976B1Battery, battery module, battery pack and electric vehicle

Publication Date: 2025.12.03 BYD CO LTD

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AI summary

Disclosed are a battery, a battery module, a battery pack, and an electric vehicle. The battery includes a housing and at least two electrode core sets. The housing has an accommodating cavity therein. The at least two electrode core sets are arranged in the accommodating cavity and connected in series with each other. Each electrode core set includes at least one electrode core (4). The battery further includes separators. The separators each are arranged between two adjacent electrode core sets. The separator includes a first separator (13) and a second separator (14). A gap is provided between the first separator (13) and the second separator (14).