Battery structure and battery housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs for vehicles have low gravimetric and volumetric energy density due to structural elements, leading to increased weight and reduced efficiency.
Innovation Solution
A battery assembly design featuring a battery housing made from a cost-effective, non-structural material and a separate battery structure made from a thermally conductive material, where the battery cells are supported by the structure and housed in a sealed enclosure, allowing for improved sealing, reduced weight, and enhanced thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional battery packs use integrated structural elements for housing and support, then structural strength is maintained, but weight increases and gravimetric energy density decreases
Solution Approach 1:
The patent divides the battery pack into separate functional components: a housing made from one material and a support structure made from a different material. This segmentation allows each component to be optimized independently - the housing for protection and sealing, and the support structure for mechanical strength with minimal weight, thereby resolving the contradiction between weight reduction and structural strength maintenance.
Solution Approach 2:
The patent employs composite construction by using different materials for the housing and support structure. The housing may use lightweight, cost-effective materials while the support structure uses high-strength, thermally conductive materials. This composite approach enables the battery pack to achieve both reduced weight and maintained structural strength.
2Productivity
If conventional battery packs use integrated structural elements, then manufacturing is simplified, but volumetric efficiency and energy density are reduced
Solution Approach 1:
By segmenting the battery pack into modular components (housing and support structure) that can be manufactured separately and assembled, the patent enables better space utilization. Each component can be optimized for its specific function without compromising overall volumetric efficiency, while the modular assembly process remains manufacturable.
Solution Approach 2:
The patent applies local quality by giving different regions of the battery pack different properties - the housing provides external protection and sealing, while the support structure provides internal mechanical support and thermal management. This localized optimization allows each region to contribute maximally to volumetric efficiency without requiring complex integrated structures.
3Ease of manufacture
If conventional battery packs use single-material construction, then manufacturing is simpler, but thermal management and cost-effectiveness are compromised
Solution Approach 1:
The patent uses composite materials with different thermal properties for the housing and support structure. The support structure can be made from thermally conductive materials to efficiently transfer heat away from battery cells, while the housing may use cost-effective materials optimized for protection and sealing. This multi-material approach enables superior thermal management while remaining cost-effective.
Solution Approach 2:
The patent applies local quality by assigning different thermal characteristics to different parts of the battery pack. The support structure in direct contact with battery cells uses high thermal conductivity materials for active heat dissipation, while other regions use materials optimized for their specific functions, achieving effective thermal management through localized material selection.
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 design enhances gravimetric and volumetric efficiency, simplifies manufacturing, improves reliability, and facilitates easier serviceability while providing robust high-voltage protection and fire safety.
Implementation Method 1
a separate battery structure made from a thermally conductive material
Implementation Method 2
a battery housing made from a cost-effective, non-structural material and a separate battery structure made from a thermally conductive material, where the battery cells are supported by the structure and housed in a sealed enclosure
Data Source
AI summary
Disclosed are designs for batter assemblies. In some embodiments, a battery assembly includes: a battery housing is made from a first material; a battery structure disposed in the battery housing and is made from a second material different from the first material; and a battery comprising a plurality of battery cells disposed on the battery structure; and wherein the battery housing is sealed.