Inverted Battery Pack Assembly for Top-Suspended EV Cells
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Solution Overview
Problem
Existing battery pack designs for electric vehicles impose dimensional and structural limitations due to the weight of the battery cells, which are typically mounted to the vehicle floor structure, inhibiting design optimization.
Innovation Solution
An inverted battery pack design where battery cells are suspended from a top shear plate, allowing even weight distribution and freeing up design space for cross beams and bottom shear plates, using mating features such as threaded protrusions, elastic retention, and flanges to secure the cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery cells are mounted using traditional methods (hanging onto cross beams or bolting to bottom shear plate), then the structural loads are supported, but dimensional and structural limitations are imposed that inhibit design optimization
Solution Approach 1:
The patent inverts the traditional mounting approach by suspending battery cells from the top shear plate instead of mounting them to the bottom shear plate or cross beams. This inversion allows the top shear plate to actively engage and distribute loads, freeing up the bottom shear plate and cross beams for optimized structural design without mounting constraints.
Solution Approach 2:
The patent transitions from traditional bottom-up mounting to top-down suspension, utilizing the vertical dimension differently. By securing cells to the top shear plate and allowing them to hang downward, the design creates new spatial arrangements and load distribution pathways that were not accessible with conventional mounting methods.
2Ease of repair
If battery cells are secured to the bottom shear plate or cross beams, then the mounting is stable, but the serviceability of the rechargeable energy storage system is reduced
Solution Approach 1:
By inverting the mounting direction and securing cells to the top shear plate, the patent improves serviceability. This configuration allows for easier access to battery cells for maintenance and replacement operations while maintaining stable suspension through the top-mounted securing mechanism.
3Force
If traditional mounting methods are used, then battery cells are secured, but the weight distribution creates structural constraints on cross beams and bottom shear plate
Solution Approach 1:
The patent resolves the structural constraints by inverting the mounting approach. The top shear plate becomes the active load-bearing element that evenly distributes battery cell weights across the vehicle floor, while the bottom shear plate and cross beams are freed from mounting responsibilities, allowing for optimized structural design.
Solution Approach 2:
The top shear plate serves multiple functions: it acts as the vehicle floor panel, provides the mounting surface for battery cells, and distributes the weights of the battery cells across the vehicle structure. This multi-functionality eliminates the need for separate dedicated mounting structures.
Data Source
AI summary
A rechargeable energy storage system for a vehicle including a bottom shear plate and a side enclosure having a bottom end connected to the bottom shear plate. A top shear plate is connected to a top end of the side enclosure and a plurality of battery cells are suspended from a bottom of the top shear plate by corresponding mating features that secure the plurality of cells to the top shear plate.