Inverted Battery Enclosure for Stiffness and Side Impact Resistance

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Solution Overview

Problem

Existing battery packs in electric vehicles face challenges in improving torsional stiffness, modal performance, and side impact resistance, which affect efficiency, serviceability, and range.

Innovation Solution

An inverted battery assembly with a lid forming a floor and sidewalls, incorporating impact absorption features and an air gap, along with a tray and ribs to enhance structural integrity and impact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional battery pack structures are used, then material usage is reduced, but torsional stiffness and modal performance deteriorate

Engineering Contradiction:

Improvetorsional stiffnessVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The battery enclosure is inverted such that the lid forms the floor of the vehicle and the tray forms the ceiling, creating an inverted U-shape configuration. This inversion allows the battery pack to serve as a structural load-bearing component that enhances torsional stiffness and modal performance while reducing the need for separate chassis materials

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If traditional battery pack structures are used, then material usage is reduced, but side impact resistance deteriorates

Engineering Contradiction:

Improveside impact resistanceVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The inverted configuration with the lid forming the floor and tray forming the ceiling creates a structurally optimized enclosure that provides enhanced side impact resistance. The inversion allows for strategic placement of impact absorption features on the sidewalls of the lid, improving safety performance while minimizing material usage

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

Impact absorption features are strategically positioned on the sidewalls of the lid at locations most susceptible to side impacts. This localized reinforcement provides enhanced side impact resistance only where needed, rather than uniformly strengthening the entire structure

Inventive Principle:

Principle #3Local quality

3Device complexity

If battery subassemblies are attached directly to the enclosure, then structural simplicity is improved, but serviceability deteriorates

Engineering Contradiction:

Improvestructural simplicityVSAvoidserviceability

Core Design Contradiction:

Device complexityVSEase of repair

Solution Approach 1:

The battery pack is divided into modular subassemblies (battery modules, current collector assemblies) that are attached to the lid using standardized fasteners. This segmentation allows individual modules to be independently serviced or replaced without disassembling the entire battery pack, improving serviceability while maintaining structural simplicity

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250273789A1Inverted battery enclosure

Publication Date: 2025.08.28 RIVIAN HOLDINGS LLC

AI summary

Aspects of the subject technology relate to an inverted battery enclosure, such as an inverted battery enclosure for a battery pack for a vehicle. The inverted battery enclosure may include a lid, and one or more battery cells and/or battery subassemblies attached to an interior surface of the lid. A gap may be provided, within the enclosure, between the battery cells and a bottom of the enclosure. One or more impact absorption features may be provided along a sidewall of the lid.