Complex-Shaped Battery Pack Layout for Frame Rail Installation
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Solution Overview
Problem
Existing battery packs for commercial vehicles face challenges in optimizing spatial utilization, weight distribution, and structural integrity while ensuring easy installation and removal, particularly when installed next to or between frame rails.
Innovation Solution
The battery pack design features L-shaped, double L-shaped, and stepped-profile configurations that conform to a vehicle's installation envelope, allowing for mirrored arrangements across a longitudinal midplane, with modular and removably installed batteries that share common planes, and include attachment features for secure mounting to frame rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional rectangular battery packs are installed in battery bays, then installation is simple, but spatial utilization is poor and weight distribution is unbalanced
Solution Approach 1:
The battery pack is divided into multiple battery modules arranged in a segmented configuration (L-shaped, double L-shaped, or stepped-profile) rather than a single rectangular block. This segmentation allows the battery pack to conform to the irregular battery bay space, improving spatial utilization while maintaining manageable complexity through modular design
Solution Approach 2:
The battery pack design transitions from a traditional two-dimensional rectangular layout to a three-dimensional multi-level configuration with battery modules arranged at different heights and positions. This dimensional change enables the battery pack to utilize vertical space and irregular volumes in the battery bay, significantly improving spatial utilization
2Quantity of substance
If battery packs are designed for maximum capacity, then energy density increases, but installation and removal become difficult
Solution Approach 1:
The battery pack is segmented into multiple independent battery modules that can be individually accessed and removed. This segmentation allows for easier installation and removal operations while maintaining maximum battery capacity, as modules can be handled separately rather than requiring removal of a single large integrated unit
Solution Approach 2:
The battery pack design incorporates universal mounting features and standardized interfaces that enable the same high-capacity battery pack to be installed and removed using standard tools and procedures. The modular architecture provides multi-functionality, allowing the battery pack to maintain maximum capacity while facilitating easy serviceability
3Strength
If battery packs are secured to frame rails, then structural integrity improves, but installation complexity increases
Solution Approach 1:
The attachment system is segmented into multiple discrete mounting points distributed across the battery pack structure. Each mounting point provides localized structural reinforcement and attachment capability, achieving overall structural integrity through distributed simple connections rather than a single complex attachment mechanism
Solution Approach 2:
The attachment features are merged with the battery module housings and mounting brackets, combining structural support and attachment functions into integrated components. This merging simplifies the overall attachment system by eliminating separate complex fastening mechanisms while maintaining structural integrity through the unified design
Data Source
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AI summary
An energy storage system may include a battery bay defining an installation design envelope. In addition, the energy storage system may include a plurality of batteries, each battery including: a casing designed to protect internal components of the battery, the casing defining an outer profile with a plurality of battery legs, including a first battery leg in a first orientation and a second battery leg in a second orientation different from the first orientation, where the second battery leg extends away from the first battery leg, and a set of battery cells arranged within the casing to form the outer profile. The energy storage system may include where the outer profiles of the plurality of batteries are configured to fit within the installation design envelope, and at least two of the batteries are mirrored across a longitudinal midplane of the installation design envelope such that the first battery legs of the mirrored batteries are positioned at opposite outboard sections of the installation design envelope.