Battery Pack Cell Sequence Structure for High Strength and Space Use
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Solution Overview
Problem
Existing battery packs for electric vehicles have a complex structure that increases weight, reduces space utilization, and complicates the assembly process, leading to low energy density and high production costs.
Innovation Solution
A battery pack design featuring a housing with a battery assembly that includes a cell sequence connected by a structural reinforcing member, which enhances structural strength, simplifies assembly, and improves space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural members (end plates, side plates, reinforcing beam, fasteners) are added to improve battery pack strength, then structural strength is improved, but weight increases and space utilization decreases
Solution Approach 1:
The patent combines the structural reinforcing function and the battery module housing function into a single integrated structure. The housing itself is designed to provide structural support, eliminating the need for separate reinforcing beams and plates, thereby reducing weight while maintaining strength.
Solution Approach 2:
The housing serves multiple functions simultaneously: it contains the battery modules, provides structural strength, and acts as the outer shell. This multi-functionality eliminates the need for dedicated reinforcing components, reducing overall weight and improving space utilization.
2Strength
If structural members (end plates, side plates, reinforcing beam, fasteners) are added to improve battery pack strength, then structural strength is improved, but space utilization of pack body decreases
Solution Approach 1:
The housing is designed to perform both containment and structural support functions, eliminating the need for separate reinforcing components that would occupy internal space, thereby maximizing the volume available for battery modules.
Solution Approach 2:
The patent removes unnecessary structural members (separate reinforcing beams, end plates, side plates) from the design, retaining only the essential housing structure, thereby freeing up internal space for battery module placement.
3Strength
If cells are assembled into battery modules first and then mounted in pack body, then structural strength is improved, but assembly process becomes cumbersome and complex
Solution Approach 1:
The battery pack is divided into independent battery units that can be assembled and tested separately, then easily mounted into the housing. This segmentation simplifies the overall assembly process while maintaining structural integrity through the integrated housing design.
Solution Approach 2:
The housing is pre-designed with integrated structural features that provide strength before the battery units are installed. This preliminary structural preparation eliminates the need for complex post-assembly reinforcement, simplifying the overall assembly process.
4Temperature
If liquid cooling plate with accommodating cavity is used for cooling, then cooling effect is improved, but structural strength decreases and plate thickness increases
Solution Approach 1:
The cooling plate is constructed using composite materials or a sandwich structure that provides both effective cooling channels and high structural strength. This allows the plate to maintain sufficient thickness for cooling while achieving the required mechanical strength to support battery modules.
Solution Approach 2:
The cooling plate is designed with varying thickness or reinforcement at critical locations where structural strength is needed, while maintaining thinner sections in areas dedicated to cooling channels, optimizing both cooling performance and structural strength.
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 design achieves a higher structural strength, reduced weight, simplified assembly, and improved energy density, leading to enhanced battery life and reduced production costs for electric vehicles.
Implementation Method 1
The structural reinforcing member is fixedly bonded with the first lateral surfaces of the cells connected with the structural reinforcing member
Data Source
AI summary
A battery pack includes a housing having a bottom surface and a top surface and a battery assembly in the housing. The battery assembly includes structural reinforcing members and cell sequences formed by connecting multiple cells. An outer surface of the cell includes a bottom surface, a top surface, first and second lateral surfaces. The bottom surface of the cell faces the bottom surface of the housing, and the top surface of the cell faces the top surface of the housing. The first lateral surface has a largest area. The multiple cells are arranged with second lateral surfaces thereof facing each other to form a cell sequence, and the structural reinforcing members are fixedly bonded with first lateral surfaces of cells in the cell sequence. The battery assembly is supported in the housing by the bottom surface of the housing.