Compressible Battery Modules with Moveable Arrays

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Solution Overview

Problem

Conventional battery designs for electrified vehicles lack effective mechanisms to absorb impact forces without increasing size or weight, potentially leading to damage during collisions.

Innovation Solution

The battery design incorporates a plurality of battery arrays arranged in a floating manner within a deformable housing, supported by elastically or plastically deformable elements that absorb collision forces, allowing the arrays to move away from the deformed housing and reducing the risk of damage, while also enabling thermal management through cooling channels and automatic separation of electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery designs are used with rigid housing and fixed battery arrays, then structural stability is maintained, but impact force absorption is insufficient leading to potential damage during collisions

Engineering Contradiction:

Improveimpact force absorptionVSAvoidstructural stability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The battery arrays are arranged in a floating manner within the battery housing, allowing them to move relative to the housing during impact. The deformable supports enable dynamic adjustment of battery array position based on impact forces, transitioning from a static fixed arrangement to a dynamic responsive system that absorbs impact energy while maintaining structural integrity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Deformable supports are pre-installed between the battery housing and battery arrays, as well as between adjacent battery arrays. These supports are designed to deform elastically or plastically upon impact, providing beforehand cushioning that absorbs impact forces before they can damage the battery arrays or housing structure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If deformable supports are added between battery arrays and housing, then impact absorption is improved, but device complexity increases

Engineering Contradiction:

Improvecollision force absorptionVSAvoidbattery module structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The deformable supports function as flexible structural elements that deform under impact loads. These supports can be made from elastomeric materials or foamed plastics that provide cushioning through elastic or plastic deformation, absorbing collision forces without requiring complex mechanical shock absorption mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The supports are designed with specific material properties (elastic or plastic deformability) that change their mechanical parameters under impact conditions. This allows simple structural elements to provide sophisticated impact absorption through material property changes rather than complex mechanical designs.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If battery arrays are arranged in floating manner with deformable supports, then impact energy is absorbed, but manufacturing precision requirements increase

Engineering Contradiction:

Improveimpact energy absorptionVSAvoidbattery array positioning

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The battery system is segmented into modular battery arrays that can be independently positioned and supported. The deformable supports are distributed at multiple locations between the housing and arrays, as well as between adjacent arrays, creating a segmented support system that accommodates manufacturing tolerances while providing comprehensive impact protection.

Inventive Principle:

Principle #1Segmentation

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 enhances safety by absorbing collision forces, reducing the risk of battery array damage, and allows for a lighter, more cost-effective battery system with improved thermal management and prevention of high-voltage short circuits during impacts.

Implementation Method 1

a plurality of deformable supports, of which some are arranged in transverse spaces between adjacent ones of the plurality of battery arrays... the deformable supports are one of plastically deformable and elastically deformable

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

the deformable supports are one of plastically deformable and elastically deformable

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 3

the deformable supports at least partially define a channel configured to direct thermal exchange fluid therethrough

Methodology Applied

Scientific EffectThermal convection: Convection

Data Source

PatentUS10862086B2Battery for electrified vehicle including compressible battery modules with moveable battery arrays

Publication Date: 2020.12.08 FORD GLOBAL TECH LLC

AI summary

A battery for an electrified vehicle according to an exemplary aspect of this disclosure includes, among other things, a battery housing, a battery module within the battery housing and extending in a transverse direction of the electrified vehicle, a plurality of battery arrays arranged within the battery module, the battery arrays arranged in a floating manner within the battery module, and a plurality of deformable supports, some of which are arranged in transverse spaces between adjacent ones of the plurality of battery arrays.