Hexagonal Battery Module Layout for Dense Vehicle Pack Integration
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Solution Overview
Problem
Existing battery modules face challenges in maximizing energy density, minimizing dead space, and maintaining structural rigidity and cooling efficiency, particularly in vehicles with limited installation spaces.
Innovation Solution
A battery module design featuring a hexagonal planar shape with split plates and a central pin holder for cell stacks, a hexagonal pillar module housing, and a bus bar frame assembly with a cooling fluid passage, enhancing space utilization, structural rigidity, and cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the battery pack shape is limited according to OEM vehicle specifications, then the battery module can be easily installed, but dead space occurs near wheel houses leading to reduced energy density
Solution Approach 1:
The battery module is divided into three separate cell stacks arranged in a triangular pattern within the hexagonal housing. This segmentation allows the battery pack to be configured in modular units that can be arranged to fill irregular spaces more efficiently, reducing dead space while maintaining adaptability to different vehicle specifications
Solution Approach 2:
The patent transitions from conventional linear or rectangular battery pack arrangements to a hexagonal geometry with triangular cell stack configuration. This dimensional change in spatial arrangement enables better utilization of three-dimensional space, particularly in areas with irregular boundaries such as near wheel houses, thereby improving energy density without sacrificing adaptability
2Ease of manufacture
If the battery module uses a conventional rectangular structure, then manufacturing is simple, but space utilization in irregular vehicle spaces is poor
Solution Approach 1:
The patent employs a hexagonal pillar shape with curved transitional surfaces between the hexagonal sections. This geometric approach allows the battery module to conform to irregular vehicle spaces more effectively than rigid rectangular structures, improving space utilization while maintaining manufacturing feasibility through standardized forming processes for the hexagonal geometry
3Quantity of substance
If the battery module increases energy density, then more battery capacity is achieved, but cooling efficiency and structural rigidity may decrease
Solution Approach 1:
The hexagonal housing incorporates localized cooling channels within the wall structures and at strategic positions around each cell stack. This local quality approach ensures that cooling capacity is concentrated where heat generation is highest, maintaining effective cooling efficiency even as battery capacity and energy density increase
Solution Approach 2:
The housing structure utilizes composite material construction combining high-strength materials for structural rigidity with thermally conductive materials for cooling efficiency. This composite approach allows the structure to maintain mechanical strength despite increased battery density, while simultaneously providing effective heat dissipation pathways
4Quantity of substance
If the battery module uses irregular hexagonal shape, then dead space is minimized, but manufacturing complexity increases
Solution Approach 1:
The hexagonal battery module is segmented into three identical triangular cell stack arrangements around a central axis. This segmentation creates a repeating pattern that simplifies manufacturing processes, as each cell stack can be produced using the same tooling and assembly procedures, thereby reducing overall manufacturing complexity despite the irregular external geometry
Solution Approach 2:
The hexagonal housing structure serves multiple functions simultaneously: it provides the outer containment shell, incorporates integrated cooling channels, supports the internal cell stack mounting structure, and enables efficient space utilization. This multi-functionality reduces the need for separate components, thereby simplifying the overall manufacturing process despite the complex geometry
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 design minimizes dead space, improves energy density, and maintains structural rigidity while ensuring effective cooling, optimizing battery pack performance in diverse vehicle installations.
Implementation Method 1
the mounting pin has a flow path formed by penetrating a central portion thereof to allow a cooling fluid to pass therethrough
Data Source
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AI summary
A battery module includes three cell stacks including: a plurality of battery cells; a cell tray including a base plate on which the three cell stacks are seated, and three split plates disposed upright on the base plate and configured to partition a space so that the three cell stacks may be disposed in spaces separated from each other; a module housing configured to accommodate the three cell stacks and the cell tray, and having a hexagonal pillar shape; and a bus bar frame assembly configured to cover an opening formed in an upper portion of the module housing and electrically connecting the plurality of battery cells.