Folded Battery Pack Enclosure for Rigid Cell Stack Packaging
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Solution Overview
Problem
Existing traction battery pack enclosures face challenges in efficiently accommodating cell stacks due to limitations in space utilization and structural rigidity, particularly when compared to deep-drawn enclosures.
Innovation Solution
The use of a folded enclosure piece made from metal or metal alloy, which is adhesively secured to a skid plate and forms a channel to house the cell stack, providing enhanced space efficiency and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a deep-drawn enclosure is used, then structural rigidity is improved, but space utilization deteriorates
Solution Approach 1:
The enclosure is divided into multiple planar sections that are folded together to form a three-dimensional structure. This segmentation allows each section to maintain structural rigidity through folding while optimizing the overall space utilization within the battery pack assembly.
Solution Approach 2:
The enclosure transitions from a two-dimensional sheet to a three-dimensional folded structure, creating vertical channels and compartments that efficiently accommodate cell stacks. This dimensional transformation enables rigid structural support while maximizing space utilization in the vertical dimension.
2Volume of moving object
If a folded enclosure piece is used, then space efficiency is improved, but structural rigidity deteriorates
Solution Approach 1:
The folded enclosure piece is constructed from metal or metal alloy materials that provide inherent structural rigidity. The combination of the folded geometric structure with high-strength metallic materials ensures that space efficiency is improved while structural rigidity is maintained or enhanced.
3Strength
If multiple enclosure pieces are joined together, then structural support is improved, but device complexity increases
Solution Approach 1:
Multiple enclosure pieces are joined together to form an integrated folded enclosure assembly that provides structural support for the cell stacks. The joining of these pieces creates a unified structure that enhances structural support while the modular design allows for efficient assembly and manufacturing.
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 solution allows for a more compact and rigid enclosure assembly that effectively supports the cell stack, improving the overall performance and packaging efficiency of traction battery packs.
Implementation Method 1
the folded enclosure piece is adhesively secured to a skid plate
Data Source
AI summary
A traction battery pack assembly includes an enclosure assembly having a folded enclosure piece and at least one cell stack within an interior of the enclosure assembly. The folded enclosure piece includes a first section that is folded along an axis relative to a second section. The at least one cell stack has one or more battery cells.