Battery Module Frame Architecture Without Internal Walls
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Solution Overview
Problem
Current electric vehicle batteries are not well-suited for large-scale production due to their size, weight, and complexity, which poses a challenge for production efficiency and mechanical rigidity, and they require additional components that increase weight and reduce available space for cells.
Innovation Solution
A battery architecture that eliminates longitudinal and transverse walls by using a frame with lateral supports and reinforcement profiles that extend between them, connected by rigid connection devices, which simplify assembly, reduce mass, and enhance mechanical rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If longitudinal and transverse walls are used to define individual housings for modules, then mechanical support and structural rigidity are provided, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the longitudinal and transverse walls from the battery assembly, extracting the problematic components that caused complexity and cost issues. The modules are held in place through alternative means (connection devices and frame structure) rather than through the traditional wall-based housing system, thereby simplifying the overall device while maintaining structural integrity
Solution Approach 2:
The connection devices serve multiple functions: they electrically connect cells within modules, provide mechanical support for the modules, and replace the structural role previously fulfilled by longitudinal and transverse walls. This multi-functionality reduces the number of components needed and simplifies the overall assembly
2Strength
If longitudinal and transverse walls are used to define individual housings for modules, then mechanical support is provided, but battery mass increases
Solution Approach 1:
The patent extracts and removes the heavy longitudinal and transverse wall structures from the battery assembly. By eliminating these mass-intensive components, the overall battery mass is reduced while alternative lightweight support mechanisms (connection devices and frame) provide the necessary mechanical support
3Stability of the object's composition
If longitudinal and transverse walls are used to define individual housings for modules, then module containment is achieved, but available volume for cells is reduced
Solution Approach 1:
The patent removes the longitudinal and transverse walls that were consuming valuable internal volume within the battery assembly. By extracting these components, more space becomes available for accommodating electrochemical cells, thereby increasing the cell volume and energy density of the battery
Solution Approach 2:
The patent reorganizes the spatial arrangement of modules and connection devices to optimize volume utilization. Modules are positioned and connected in a configuration that maximizes the use of available space without requiring the traditional wall-based compartmentalization, effectively utilizing the three-dimensional space more efficiently
4Strength
If additional stiffening components such as stiffening rods are used to enhance mechanical rigidity, then structural strength is improved, but device complexity and weight increase
Solution Approach 1:
The connection devices are designed to perform multiple functions simultaneously: electrical connection of cells, mechanical support of modules, and structural stiffening of the battery assembly. By making the connection devices multi-functional, the patent eliminates the need for separate stiffening components like stiffening rods, thereby reducing device complexity and weight while maintaining or improving mechanical rigidity
Data Source
Figure 1~2
Figure 3~4
AI summary
A secondary battery (2) comprising: - a frame (3) comprising a first lateral support (4) and a second lateral support (5) defining between them a receiving zone (6), - a plurality of modules (7) arranged in the receiving zone (6), each module (7) having a first framework (8) and a second framework (9), in which battery (2) the first framework (8) and the second framework (9) extend from the first lateral support (4) to the second lateral support (5) and the first framework (8) and the second framework (9) are each fixed to the first lateral support (4) and to the second lateral support (5).