Unified Battery Module Structural Adhesive Integration
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Solution Overview
Problem
Conventional battery modules for electric vehicles are large, heavy, and costly due to their design, which increases the risk of failure and reduces safety in the event of impacts, as well as being inefficient in terms of space and weight.
Innovation Solution
A unified battery module design using structural foam, adhesive, and interconnecting carrier halves to provide impact resistance, thermal insulation, and dielectric barriers, with a structural adhesive that connects battery cells and housing components, allowing for a lightweight and compact structure that absorbs forces and distributes impact across a larger area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional battery module design is used, then structural support and safety are provided, but the module becomes large, heavy, and costly
Solution Approach 1:
The patent combines the structural support function with the battery cell housing into a single integrated component. The structural support is formed as an integral part of the cell housing rather than being a separate element, merging two functions into one component to reduce overall weight and complexity.
Solution Approach 2:
The patent employs composite material construction for the cell housing that provides both structural integrity and lightweight properties. The housing is designed as a composite structure that achieves high strength-to-weight ratio, combining multiple materials or structural features to simultaneously provide support and reduce mass.
2Strength
If conventional battery module design with multiple components is used, then structural support is provided, but the number of components increases failure risk
Solution Approach 1:
The patent integrates multiple functions into fewer components. The structural support is merged with the cell housing, and the housing itself is designed to provide both containment and structural reinforcement. This reduction in component count directly lowers the probability of failure points in the system.
3Strength
If conventional battery module design is used, then structural integrity is maintained, but space efficiency and packaging density are reduced
Solution Approach 1:
The patent segments the structural support function into distributed reinforcement features integrated throughout the cell housing structure rather than requiring a single large external frame. This allows more efficient use of space within the module while maintaining overall structural integrity.
4Force
If conventional battery module design with external safety structures is used, then impact resistance is provided, but the module becomes larger and heavier
Solution Approach 1:
The patent merges the impact resistance function into the cell housing structure itself. The housing is designed with integrated reinforcement features that provide crash and impact protection without requiring separate external safety structures, thereby reducing overall weight.
Solution Approach 2:
The patent applies local reinforcement features at specific locations within the cell housing where impact forces are most likely to occur. Rather than uniformly thickening the entire housing structure, strategic local strengthening provides adequate impact resistance with minimal additional weight.
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 solution reduces the risk of thermal events and non-passive failures by distributing impact forces, providing a safer and more efficient energy storage system with potential cost savings through reduced material usage and improved packaging density.
Implementation Method 1
a structural adhesive disposed in the first volume of the housing and around each battery cell in the array of battery cells, the structural adhesive filling the open volume surrounding each battery cell mechanically coupling each battery cell in the array of battery cells together
Implementation Method 2
providing a safer and more efficient energy storage system with potential cost savings through reduced material usage and improved packaging density
Data Source
AI summary
An energy storage device and structurally enhanced packaging for energy storage cells is provided. The energy storage device includes a number of energy storage cells spaced apart from one another and contained in a lightweight carrier. The energy storage cells and carrier are mechanically coupled together with a structural adhesive forming a unified structure and framework where each connection point acts as a node in a force distribution structure. The structural adhesive can be injected into the volume between the energy storage cells while in a fluid, or semi-fluid, state. While in this state, a retaining form or gasket inside the carrier can prevent the structural adhesive from leaking out of the energy storage device. When in a cured, or hardened, non-fluid state the structural adhesive may adhere to the various components of the energy storage device to mechanically join the component together into a structurally safe package.