Structural EV Battery Cell Matrix for Crash-Safe Pack Integration
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Solution Overview
Problem
Existing battery electric vehicles face challenges in maximizing volumetric efficiency, weight reduction, and crash safety while integrating battery packs as a structural part of the vehicle body, with current designs often requiring multiple components and gaps that compromise space efficiency and increase vehicle size.
Innovation Solution
A battery frame structure with accommodating cavities holds battery cells in place using a flowable bonding substance, forming a rigid and integral brick that reduces the need for fasteners and allows for a compact, impact-resistant battery pack that can be easily integrated into the vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional standalone battery pack design with safety cage and gaps is used, then crash safety and cell protection are improved, but volumetric efficiency deteriorates and vehicle size increases
Solution Approach 1:
The patent merges the battery pack structure with the vehicle body structure by integrating the battery casing to form the bottom of the vehicle body and removing the traditional front floor. This integration eliminates the need for separate safety cages and gaps, achieving both crash safety and improved volumetric efficiency simultaneously.
Solution Approach 2:
The battery pack structure serves multiple functions: it acts as the vehicle body bottom, provides crash safety protection, and eliminates the need for separate floor structures. This multi-functionality resolves the contradiction by making the same structure serve both safety and space-efficient purposes.
2Stability of the object's composition
If multiple fastener members (end plates, bolt fixations, tension straps) are used to secure battery cells, then cell positioning stability is improved, but device complexity and weight increase
Solution Approach 1:
The patent extracts and eliminates the need for multiple fastener members (end plates, bolt fixations, tension straps) by using a resin bonding substance that directly secures battery cells to the battery pack structure. This reduction in components decreases device complexity and weight while maintaining cell positioning stability.
Solution Approach 2:
The patent replaces the mechanical fastening system (multiple fastener members) with a chemical bonding system (resin bonding substance). This substitution simplifies the structure by eliminating complex mechanical assemblies while providing stable cell positioning through adhesive bonding.
3Quantity of substance
If larger footprint is used to compensate for lower volumetric efficiency, then cell volume capacity is improved, but vehicle size and stopping distance increase
Solution Approach 1:
By merging the battery pack with the vehicle body structure and eliminating gaps and tolerances, the patent achieves higher volumetric efficiency. This allows more cell volume to be packed into the same footprint, increasing capacity without increasing vehicle size.
Solution Approach 2:
The patent changes the spatial arrangement parameters by eliminating gaps and reducing tolerance spaces between components. This parameter optimization allows maximum cell density within the available volume, achieving high capacity without increasing external dimensions.
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
The solution enhances volumetric efficiency, reduces weight by 200 kg, and improves crash safety by distributing impact forces, while maintaining structural integrity and thermal management, thus optimizing the battery pack's integration into the vehicle.
Implementation Method 1
each battery cell being placed in a respective accommodating cavity and connected to adjacent walls of the respective accommodating cavity via a flowable bonding substance being inserted between the cells and the walls of the respective cavity
Data Source
AI summary
An electric vehicle including a battery assembly with at least two rows of battery cells attached to a battery frame structure. The battery frame structure has a number of accommodating cavities, arranged in a matrix, each battery cell being placed in a respective accommodating cavity and connected to adjacent walls of the respective accommodating cavity via a flowable bonding substance being inserted in a gap between the cells and the walls of the respective cavity.