Battery Pack Carrier Layout for Higher Cell Packing Density
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Solution Overview
Problem
Current battery packs in new energy vehicles have limited range due to inefficient space utilization in the battery pack design, which restricts the energy density and overall performance.
Innovation Solution
A battery pack design featuring a box body with a carrier having a planar carrying surface that maintains equal distances with battery cells, allowing for higher space utilization and energy density, along with a carrier that can be integrated into the vehicle chassis to enhance structural strength and reduce driving resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the carrying surface is constructed as a non-planar surface (e.g., curved surface), then the structural strength and aerodynamic performance may be improved, but the space utilization rate decreases and energy density is reduced
Solution Approach 1:
The patent changes the geometric parameter of the carrying surface from non-planar (curved) to planar, optimizing the space utilization rate. The planar surface allows battery cells to be arranged in a regular grid pattern with uniform spacing, maximizing the number of cells that can be accommodated in the battery pack, thereby increasing energy density.
Solution Approach 2:
The carrier is designed with a planar carrying surface that serves multiple functions: it provides structural support for the battery cells, enables efficient space utilization through regular arrangement, and maintains structural strength through its integration with the box body framework. The connecting portion of the carrier also provides multi-functionality by both supporting the carrying portion and connecting to the box body.
2Quantity of substance
If more battery cells are accommodated in the battery pack, then the energy density and range are improved, but the structural complexity increases
Solution Approach 1:
The patent divides the battery pack structure into modular components: the box body, the carrier with carrying portion and connecting portion, and multiple battery cells. This segmentation allows for standardized, repeatable units that can be systematically arranged to accommodate more cells without proportionally increasing overall structural complexity. The modular carrier design can be replicated across the battery pack.
Solution Approach 2:
The carrier is nested within the box body structure, with the connecting portion integrated into the box body framework. This nesting approach allows the carrier to utilize the existing structural space of the box body, accommodating more battery cells without requiring additional external structural elements that would increase complexity.
3Strength
If the carrier is integrated into the vehicle chassis, then the structural strength is improved and driving resistance is reduced, but the ease of repair decreases
Solution Approach 1:
The patent segments the carrier into distinct functional portions: the connecting portion that integrates with the vehicle chassis and the carrying portion that holds the battery cells. This segmentation allows the battery cells to be serviced by accessing only the carrying portion, while the integrated connecting portion remains part of the chassis structure, balancing structural strength with repairability.
4Quantity of substance
If the carrying surface maintains equal distances with battery cells, then the space utilization rate is maximized, but the manufacturing precision requirements increase
Solution Approach 1:
The patent standardizes the geometric parameters of the planar carrying surface and the positioning features for battery cells. By defining uniform spacing and standardized mounting interfaces, the manufacturing precision requirements are made explicit and controllable, allowing for high space utilization through regular, repeatable patterns rather than complex custom positioning for each cell.
Data Source
AI summary
The present application relates to a battery pack and an electrical apparatus, including a box body and a battery cell. The box body encloses to form an accommodating cavity, the box body includes a carrier located at its top and used for defining the accommodating cavity, and the battery cell is accommodated in the accommodating cavity. A carrying surface of the carrier facing the accommodating cavity is constructed as a plane, and the battery cell is arranged on the carrying surface.