Beam-Integrated Battery Pack Structure for Dense Cell Packaging
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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 reduced capacity, as they isolate cells from structural supports to prevent failure spread, resulting in inefficient use of space and reduced 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 closer cell spacing and increased volumetric energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are isolated from structural supports to prevent failure spread, then reliability is improved, but volumetric energy density deteriorates due to inefficient space use
Solution Approach 1:
The patent merges the structural support function with the battery cell containment function by integrating cells directly into the longitudinal beam structure. The cells are positioned within recesses of the beam, eliminating the need for separate insulation barriers while maintaining structural integrity and failure containment.
Solution Approach 2:
The longitudinal beam serves multiple functions simultaneously: it provides structural support for the battery pack, contains the battery cells within its recesses, and acts as a thermal management pathway. This multi-functionality eliminates the need for dedicated insulation components, increasing volumetric energy density.
2Quantity of substance
If battery cells are placed compactly to increase energy density, then volumetric energy density is improved, but thermal management deteriorates due to heat accumulation
Solution Approach 1:
The longitudinal beam acts as an intermediary thermal management component. It provides direct thermal contact with multiple battery cells simultaneously, serving as a heat sink and conduction pathway. This mediator approach enables efficient heat dissipation from compactly arranged cells without requiring additional thermal management hardware.
3Reliability
If insulation is added to prevent thermal runaway spread, then reliability is improved, but device complexity increases due to additional components
Solution Approach 1:
The structural beam and thermal containment functions are merged into a single integrated component. The longitudinal beam's geometry and material properties provide both mechanical support and thermal management, eliminating the need for separate insulation layers or barriers.
Solution Approach 2:
The longitudinal beam performs multiple functions: structural support, cell containment, and thermal management. This multi-functionality reduces the overall component count and simplifies the battery pack design while maintaining thermal runaway prevention capabilities.
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.