Module-Less Battery Pack Structure for Higher Energy Density
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Solution Overview
Problem
Conventional battery packs for vehicles have low gravimetric and volumetric energy density due to structural elements, which increase weight and reduce efficiency.
Innovation Solution
A battery pack design featuring a thermal plate with adhesive slots for individual cells, a BMU tray, cross braces, and encapsulating foam, along with a method of assembly that includes laser welding busbars and bonding BMUs, to enhance structural rigidity and efficiency while minimizing weight and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple battery sub-packs with modules and frames are used, then structural stability is improved, but weight increases and energy density decreases
Solution Approach 1:
The patent divides the battery pack into individual cell-level slots within a single pack housing, eliminating the need for multiple sub-packs and intermediate frames. Each cell is independently mounted in its own slot with adhesive and encapsulating foam, providing structural stability at the cell level without requiring heavy sub-pack assemblies.
Solution Approach 2:
The patent removes the intermediate sub-pack modules and their associated frames from the design. By directly mounting individual battery cells into slots within the pack housing, the design extracts and eliminates the unnecessary structural layers that added weight and complexity.
2Stability of the object's composition
If multiple battery sub-packs with modules and frames are used, then structural stability is improved, but volumetric energy density decreases
Solution Approach 1:
The pack housing is segmented into multiple slots that directly accommodate individual battery cells, eliminating the volumetric overhead of sub-pack modules and frames. This cell-level segmentation allows for optimal space utilization and reduces the overall pack volume.
Solution Approach 2:
The patent merges the functions of multiple sub-pack modules into a single integrated pack housing structure. By combining the housing, thermal management, and cell mounting functions into one unified structure, the design eliminates redundant structural elements and reduces total volume.
3Temperature
If thermal plate and adhesive slots are integrated into pack housing, then heat transfer efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The thermal plate is merged with the pack housing into a single integrated component. The housing itself is designed with built-in thermal conduction pathways and adhesive slots, combining structural support and thermal management functions into one piece that can be manufactured as a single unit.
Solution Approach 2:
The pack housing serves multiple functions simultaneously: it provides structural support, thermal conduction pathways, adhesive bonding surfaces, and cell positioning slots. This multi-functionality reduces the number of separate components and simplifies the manufacturing process.
4Volume of moving object
If individual battery cells are directly mounted in slots with adhesive, then volumetric efficiency is improved, but mechanical bonding strength may be reduced
Solution Approach 1:
The patent uses a composite bonding approach combining adhesive materials with encapsulating foam. The adhesive provides initial bonding strength while the cured foam provides additional mechanical support and strain distribution, creating a composite bonding system that maintains strength while minimizing cell volume.
Solution Approach 2:
The encapsulating foam is applied beforehand to provide cushioning and distribute mechanical stresses around the battery cells. This pre-applied foam layer protects the cells from shock and vibration while maintaining strong mechanical bonding through the adhesive.
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 improves gravimetric and volumetric efficiency by reducing structural elements and facilitating efficient heat transfer, resulting in a lighter and more energy-dense battery pack.
Implementation Method 1
adhesive disposed in the plurality of slots. The plurality of individual battery cells can be in contact with the adhesive and mechanically bonded to the thermal plate via the adhesive
Implementation Method 2
a thermal plate positioned between the bottom cover and the pack housing
Implementation Method 3
an encapsulating foam disposed in expansion gaps between adjacent battery cells of the plurality of individual battery cells
Implementation Method 4
laser welding a plurality of busbars onto the plurality of individual battery cells
Data Source
AI summary
Disclosed herein are devices, systems, and methods relating to a battery pack. In an example, a battery back can include a bottom cover and a pack housing coupled to the bottom cover. The pack housing can include a plurality of slots for a plurality of individual battery cells. The battery pack can include a thermal plate positioned between the bottom cover and the pack housing. The battery pack can include adhesive disposed in the plurality of slots. The battery pack can include the plurality of individual battery cells disposed respectively in the plurality of slots. The plurality of individual battery cells can be in contact with the adhesive.