Complex-Shaped Battery Pack Layout for Vehicle Envelope Fit
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Solution Overview
Problem
Existing battery packs for commercial vehicles face challenges in optimizing spatial utilization, weight distribution, and structural integrity while ensuring efficient installation, serviceability, and thermal management.
Innovation Solution
The battery pack design features L-shaped, double L-shaped, and stepped-profile configurations that conform to a vehicle's installation envelope, allowing mirrored battery arrangements across a longitudinal midplane, with modular components for secure mounting and adaptable thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional rectangular battery packs are used, then manufacturing is simple, but spatial utilization is poor
Solution Approach 1:
The battery pack is divided into multiple legs or modules that can be independently arranged to form complex shapes (L-shaped, U-shaped, stepped profiles). Each leg contains battery cells organized in separate sections, allowing the overall structure to conform to irregular installation envelopes while maintaining modular assembly and manufacturing simplicity
Solution Approach 2:
The battery pack design extends from traditional two-dimensional rectangular layouts to three-dimensional complex geometries with multiple legs and varying heights. This dimensional expansion allows the battery system to utilize vertical space and irregular volumes within the vehicle chassis, transforming unused spaces into functional energy storage areas
2Volume of moving object
If battery packs are custom-shaped to fit vehicle envelopes, then spatial utilization improves, but manufacturing complexity increases
Solution Approach 1:
The battery pack is divided into multiple legs or modules that can be independently arranged to form complex shapes (L-shaped, U-shaped, stepped profiles). Each leg contains battery cells organized in separate sections, allowing the overall structure to conform to irregular installation envelopes while maintaining modular assembly and manufacturing simplicity
Solution Approach 2:
The modular leg design with standardized connection interfaces allows the same basic components to be configured in multiple shapes (L-shaped, U-shaped, stepped) to fit different vehicle platforms. This universal modular approach enables a single manufacturing process to produce various custom-shaped packs without requiring dedicated tooling for each geometry
3Quantity of substance
If multiple battery packs are installed in available spaces, then energy storage capacity increases, but weight distribution becomes unbalanced
Solution Approach 1:
The battery pack design intentionally creates asymmetrical weight distribution within each pack by positioning the center of gravity toward the front or rear, depending on vehicle requirements. When two packs are installed mirror-image opposite each other, these asymmetrical distributions balance each other out, achieving overall vehicle weight balance while maximizing total energy storage capacity
Solution Approach 2:
The battery pack design extends from traditional two-dimensional rectangular layouts to three-dimensional complex geometries with multiple legs and varying heights. This dimensional expansion allows the battery system to utilize vertical space and irregular volumes within the vehicle chassis, transforming unused spaces into functional energy storage areas
4Strength
If battery packs are designed for secure mounting to frame rails, then structural integrity improves, but installation complexity increases
Solution Approach 1:
The battery pack is pre-assembled as a complete module with all structural components, mounting features, and electrical connections integrated before delivery to the vehicle. This preliminary assembly ensures structural integrity is achieved during manufacturing under controlled conditions, while installation at the vehicle becomes a simpler process of mounting the pre-integrated module to the frame rails
Data Source
AI summary
An energy storage system may include a battery bay defining an installation design envelope. In addition, the energy storage system may include a plurality of batteries, each battery including: a casing designed to protect internal components of the battery, the casing defining an outer profile with a plurality of battery legs, including a first battery leg in a first orientation and a second battery leg in a second orientation different from the first orientation, where the second battery leg extends away from the first battery leg, and a set of battery cells arranged within the casing to form the outer profile. The energy storage system may include where the outer profiles of the plurality of batteries are configured to fit within the installation design envelope, and at least two of the batteries are mirrored across a longitudinal midplane of the installation design envelope such that the first battery legs of the mirrored batteries are positioned at opposite outboard sections of the installation design envelope.