Long-Cell Battery Pack Structure Without Beams or Screws
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Solution Overview
Problem
Existing battery packs for electric vehicles suffer from low space utilization and energy density due to the use of screws and beams, leading to inefficient use of housing volume, complex assembly processes, and increased costs, which hinders the development of electric vehicles.
Innovation Solution
A battery pack design that optimizes space utilization by arranging cells in a manner where the length of each cell is between 600-2500 mm, allowing for higher cell density without expanding the occupied space, eliminating the need for transverse beams and reducing assembly complexity, thereby improving energy density and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws and transverse beams are used to fix battery modules in the housing, then the battery modules can be securely mounted, but the space utilization of the housing is reduced and the energy density decreases
Solution Approach 1:
The patent removes the transverse beams and screws from the battery pack structure, extracting the mounting function to the housing walls themselves. The battery modules are directly fixed to the housing using adhesive or interference fit, eliminating the need for separate mounting components and maximizing the usable space within the housing.
Solution Approach 2:
The mounting function is merged with the housing structure itself. The housing walls serve both as the containment structure and as the mounting surface for battery modules, eliminating the need for separate mounting components and reducing overall structural complexity.
2Reliability
If screws and connecting members are used to fix battery modules, then the modules can be securely attached, but the weight increases and energy density is reduced
Solution Approach 1:
The patent eliminates screws and connecting members from the battery pack, removing the fastening function to adhesive bonding or interference fit. This extraction of mechanical fastening components significantly reduces the overall weight of the battery pack while maintaining secure module attachment.
Solution Approach 2:
The patent replaces permanent mechanical fastening with adhesive bonding, which can be applied and cured in place. The adhesive layer provides sufficient bonding strength without the weight penalty of metal fasteners, and any replacement can be done by simply removing the old adhesive and applying new adhesive.
3Reliability
If end beams and side beams with certain thickness and height are designed for battery modules, then the modules can be properly supported and positioned, but the space inside the housing is wasted
Solution Approach 1:
The patent removes end beams and side beams from the battery module design, extracting the support and positioning function to the housing walls and floor. Battery modules are directly supported by the housing structure, eliminating the need for additional beam structures and maximizing the internal space available for cell arrays.
Solution Approach 2:
The support and positioning function is merged with the housing structure. The housing walls and floor serve as the support and positioning elements for battery modules, eliminating the need for separate beam structures and reducing overall structural complexity.
4Reliability
If a conventional battery module assembly process with multiple steps is used, then the cells can be properly assembled and mounted, but the assembly complexity increases and labor costs rise
Solution Approach 1:
The patent segments the battery pack into individual cells that are directly mounted in the housing, eliminating the intermediate battery module assembly step. Each cell is independently positioned and fixed to the housing, simplifying the overall assembly process while maintaining proper cell arrangement and support.
Solution Approach 2:
The patent merges the cell mounting function directly to the housing structure, eliminating the separate battery module as an intermediate assembly unit. Cells are directly fixed to the housing walls and floor, combining the support, positioning, and mounting functions into a single integrated process.
Data Source
AI summary
A battery pack and an electric vehicle are provided. The battery pack includes a housing; and a plurality of cells, provided in the housing, wherein the sum V1 of the volumes of the plurality of cells and the volume V2 of the battery pack satisfy V1/V2≥255%. The battery pack has a first direction and a second direction perpendicular to each other. A length direction of the cell is arranged along the first direction of the battery pack, and the plurality of cells are arranged along the second direction of the battery pack. The cell comprises a cell body, and the length of the cell body is 400-2500 mm.