Longitudinal Beam Battery Pack Structure for Dense Cell Spacing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs face challenges in achieving high energy density and structural integrity due to compact cell placement, which leads to thermal runaway and mechanical stress, often requiring extensive insulation and isolation that reduces capacity and energy density.
Innovation Solution
The battery pack design incorporates battery cells as part of the structural support, using a longitudinal beam and side beams to facilitate load distribution, reduce insulation, and enhance heat transfer, allowing for closer cell spacing and increased volumetric energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are placed compactly to increase energy density, then volumetric energy density is improved, but thermal management becomes more difficult and structural integrity deteriorates
Solution Approach 1:
The patent merges the structural support function with the battery cell housing by designing the cells to serve dual purposes: electrical energy storage and mechanical structural support. The cells are positioned to form load-bearing structures within the pack, eliminating the need for separate structural framework and enabling compact arrangement while maintaining structural integrity.
Solution Approach 2:
The battery cells are designed to perform multiple functions simultaneously: they provide electrical energy storage, structural support for the pack, and thermal management surfaces. The cell housings serve as both containment vessels and heat dissipation surfaces, allowing compact placement without compromising thermal or structural performance.
2Quantity of substance
If battery cells are placed compactly to increase energy density, then volumetric energy density is improved, but thermal runaway risk increases
Solution Approach 1:
The patent introduces thermal management fluid channels as intermediary elements between battery cells to facilitate heat dissipation. These channels are integrated into the pack structure and positioned to efficiently remove heat from compactly arranged cells, preventing thermal accumulation that could lead to thermal runaway while maintaining high energy density.
3Reliability
If extensive insulation and isolation are used to prevent thermal runaway, then safety is improved, but energy density decreases
Solution Approach 1:
The patent converts the potentially harmful direct contact between battery cells into a beneficial thermal management opportunity. By allowing cells to be in close proximity or direct contact, the design enables efficient heat transfer between cells and to the thermal management system, turning what would normally require insulation (a space-consuming safety measure) into an opportunity for compact arrangement with active cooling.
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 design increases volumetric energy density and structural integrity by utilizing battery cells as structural components, reducing insulation and allowing for a more compact and robust battery pack with improved heat management and longer cycle life.
Implementation Method 1
The base may be a heat exchanger, and the base may define fluid channels extending orthogonally to the longitudinal beam
Data Source
AI summary
Battery packs according to some embodiments of the present technology may include a longitudinal beam. The packs may include a plurality of battery cells disposed adjacent the longitudinal beam. Each battery cell may be characterized by a first surface, and a second surface opposite the first surface. Each battery cell may be characterized by a third surface extending vertically between the first surface and the second surface. The first surface may face the longitudinal beam, and battery terminals may extend from the third surface. Each battery cell may be characterized by a fourth surface opposite the third surface. The packs may include a lid coupled with the first surface of each battery cell of the plurality of battery cells. The packs may include a base coupled with the second surface of each battery cell of the plurality of battery cells.