Battery Pack Assembly Without Internal Bars for Higher Energy Density
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Solution Overview
Problem
The use of longitudinal and latitudinal bars in electric energy storage systems for electric vehicles occupies a significant portion of the internal volume, leading to lower volumetric energy density, higher costs, and reduced electric driving range.
Innovation Solution
The solution involves removing these mechanical structures from the internal space of the battery pack and relocating them to other areas, such as the vehicle body, while ensuring mechanical stability through welding and gluing of cell modules to the pack covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If longitudinal and latitudinal bars are used to provide mechanical stability and fixation, then mechanical stability during shock and vibration is improved, but volumetric energy density deteriorates due to occupation of internal space
Solution Approach 1:
The patent removes the mechanical bars from the internal space of the battery pack and relocates them to the vehicle body structure. This extraction eliminates the space occupation by bars while maintaining mechanical stability through the relocated structural elements in the vehicle body.
Solution Approach 2:
The patent merges the function of mechanical stabilization with the vehicle body structure by integrating the bars into the vehicle body rather than keeping them as separate internal components. This combining allows the vehicle body to serve dual purposes: structural support and mechanical stabilization during shock and vibration.
2Volume of stationary object
If mechanical bars are removed from internal space, then volumetric energy density is improved, but mechanical stability during shock and vibration deteriorates
Solution Approach 1:
The patent extracts the bars from the internal battery pack space, removing the harmful occupation of volume while preserving their mechanical stabilization function by relocating them to the vehicle body structure where they continue to provide shock and vibration resistance.
Solution Approach 2:
The patent relocates the mechanical bars from the internal three-dimensional space of the battery pack to the vehicle body structure, effectively moving the stabilization function to a different spatial dimension and location while maintaining its effectiveness.
3Volume of stationary object
If structural bars are removed and cells are glued to pack cover, then volumetric energy density is improved, but bonding strength under mechanical loads deteriorates
Solution Approach 1:
The patent employs a composite fixation approach by combining welding and gluing methods to attach cell modules to the pack cover. This composite method leverages the strengths of both welding (strong mechanical bond) and gluing (distributed stress coverage) to achieve sufficient bonding strength while maintaining high volumetric energy density.
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
This approach enhances volumetric energy density, improves mechanical stability during shock and vibration, increases installed energy, extends electric vehicle driving range, and reduces costs per energy storage system.
Implementation Method 1
a first area on a first cover of the cell module is fixed onto the first pack cover by welding
Implementation Method 2
a second area on the first cover of the cell module is fixed onto the first pack cover by glue
Data Source
AI summary
A battery pack, a method for forming a battery pack and an electric vehicle are provided. The battery pack includes a first pack cover, a second pack cover, and a cell module. The second pack cover is sealed with the first pack cover to form a cavity to accommodate the cell module. A first area on a first cover of the cell module is fixed onto the first pack cover by welding. A second area on the first cover of the cell module is fixed onto the first pack cover by glue.