Battery Pack Cell Packing Structure for Higher Energy Density
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Solution Overview
Problem
Rechargeable battery packs face challenges in maximizing energy density due to inefficiencies in packing and connecting battery cells, leading to wasted space and energy storage limitations.
Innovation Solution
A rechargeable battery pack design that includes a cell pack assembly with battery cells arranged in a stacked configuration, minimizing unused space and optimizing energy storage by using a rectangular-prism shape and intermediate layers, ensuring that the combined volume of the battery cells occupies at least 80% of the cell packing volume and storing energy at a density of no less than 150 Ah/L, with a battery management system for efficient energy flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in conventional configurations, then ease of manufacture is maintained, but energy density is limited due to wasted space
Solution Approach 1:
The battery pack is divided into multiple individual battery cells, each with standardized cylindrical geometry. This segmentation allows for modular assembly and optimized packing arrangements that maximize space utilization while maintaining manufacturing simplicity through standardization.
Solution Approach 2:
The patent transitions from conventional two-dimensional planar arrangements of battery cells to a three-dimensional stacked configuration. This dimensional change enables more efficient space utilization by arranging cells vertically in layers, achieving higher energy density (≥150 Ah/L) while maintaining manageable structural complexity through repetitive modular stacking.
2Quantity of substance
If cell packing volume is increased to store more energy, then energy density improves, but the housing volume requirement increases
Solution Approach 1:
The patent changes the geometric parameters of the battery cell packing arrangement by adopting a standardized cylindrical cell design with specific dimensions. This parameter optimization allows achieving high energy density (≥150 Ah/L) within a compact housing volume by maximizing the ratio of active cell volume to total pack volume.
Solution Approach 2:
The battery pack employs a composite structural approach combining multiple cylindrical cells with intermediate members and housing components. This composite design enables efficient space utilization where cells are tightly packed in a stacked arrangement, maximizing energy storage capacity within the constrained housing volume.
3Quantity of substance
If intermediate members are reduced to minimize space waste, then energy density improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the dimensional parameters of intermediate members to achieve a balance between space utilization and manufacturing feasibility. By carefully controlling the thickness and dimensions of intermediate members, the design minimizes their volume contribution while ensuring adequate spacing for cell alignment, thereby maintaining energy density ≥150 Ah/L without excessive precision requirements.
Data Source
AI summary
A battery pack including a housing at least partially defining an interior volume therein, a docking interface, and a cell pack assembly at least partially positioned within the interior volume. The cell pack assembly includes a plurality of battery cells, where each battery cell includes a body, an anode extending from the body, and a cathode extending from the body, where the cell pack assembly defines cell packing volume in the shape of a rectangular-prism that completely encompasses each body portion of the plurality of cells, and where the cell pack assembly is packaged such that the combined volume of the body portions of each battery cell of the plurality of battery cells occupies no less than 80% of the cell packing volume.