Modular Battery Pack Side Supports for Compact Heavy-Duty Packaging
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Solution Overview
Problem
Existing battery packs for vehicles are large, heavy, and costly, posing challenges in manufacturing and space efficiency, particularly for heavy-duty applications like trucks and construction equipment.
Innovation Solution
A battery pack design featuring a housing with offset side walls and releasable side support members that allow for compact, space-efficient stacking and easy assembly, enabling a cost-effective and compact configuration with high energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional battery pack designs are used, then sufficient battery capacity is achieved, but the battery pack becomes large and heavy
Solution Approach 1:
The battery pack is divided into multiple battery modules, each comprising a plurality of battery cells arranged in stacks. This segmentation allows for optimized space utilization and reduced overall pack weight while maintaining sufficient total capacity.
Solution Approach 2:
Battery cells are arranged in a three-dimensional stacked configuration within modules, transitioning from traditional planar layouts to vertical stacking. This dimensional change maximizes energy density within the available space, achieving high capacity without proportional weight increase.
2Quantity of substance
If traditional battery pack designs are used, then sufficient battery capacity is achieved, but manufacturing costs increase
Solution Approach 1:
The modular architecture with standardized battery modules enables simplified manufacturing processes. Each module can be independently assembled and tested, reducing overall manufacturing complexity and cost while maintaining high capacity through multiple modules.
Solution Approach 2:
The side support members are designed with universal functionality, serving both as structural support elements and as attachment points for battery modules. This multi-functionality reduces the total number of components needed, lowering manufacturing costs.
3Reliability
If traditional battery pack designs are used, then battery modules are securely held, but assembly complexity increases
Solution Approach 1:
The side support members are designed to be releasably attached to the housing rather than permanently fixed. This dynamic attachment system allows for easy assembly and disassembly of battery modules while maintaining secure holding during operation, reducing assembly complexity.
Solution Approach 2:
The side support members act as intermediary elements between the housing and battery modules. They provide a simplified interface that secures modules reliably while enabling straightforward assembly and removal without complex fastening mechanisms.
4Volume of moving object
If compact battery pack configuration is achieved, then space efficiency improves, but manufacturing cost increases
Solution Approach 1:
The adoption of vertical stacking arrangements for battery cells within modules achieves compact pack volume without requiring expensive custom manufacturing processes. The standardized modular design maintains manufacturing simplicity while maximizing space utilization.
Solution Approach 2:
The side support members serve multiple functions including structural support, module attachment, and space optimization. This multi-functionality achieves compact configuration using standard, cost-effective components rather than specialized expensive parts.
Data Source
AI summary
A battery pack has a longitudinal extension in a longitudinal direction, a width extension in a width direction, and a height extension in a height direction. The battery pack includes a plurality of battery modules, wherein each battery module comprises a plurality of battery cells, a housing, wherein the housing comprises a first side wall and a second side wall having a respective extension in the longitudinal direction and the height direction, and at least one first pair of side support members for carrying at least one of the battery modules in the housing. The disclosure also relates to a method and to a vehicle.