Structural EV Battery Matrix for Crash-Safe Space Efficiency
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Solution Overview
Problem
Current electric vehicle battery packs have lower volumetric efficiency due to double structures, which occupy valuable space and increase vehicle size, leading to reduced range and increased energy content.
Innovation Solution
A battery frame structure with accommodating cavities arranged in a matrix, where battery cells are firmly bonded to the cavity walls using a flowable bonding substance, reducing the need for internal fasteners and allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional standalone battery pack structure with separate safety cage and body structure is used, then crash safety and cell protection are improved, but volumetric efficiency deteriorates due to double structures occupying valuable space
Solution Approach 1:
The patent merges the battery pack structure with the vehicle body structure by integrating the battery frame into the vehicle floor structure. The battery frame serves dual functions as both the battery containment structure and the vehicle body structural element, eliminating the need for separate safety cage and body structure. This integration maintains crash safety while improving volumetric efficiency by removing redundant structural components.
2Stability of the object's composition
If internal fastener members such as end plates, bolt fixations, and tension straps are used to secure battery cells, then cell positioning stability is improved, but device complexity and weight increase
Solution Approach 1:
The patent removes traditional internal fastener members such as end plates, bolt fixations, and tension straps from the battery pack structure. Instead, battery cells are secured through direct integration with the vehicle body structure via adhesive bonding and mechanical interlocking with the frame structure. This extraction of unnecessary fastening components simplifies the device structure and reduces weight while maintaining cell positioning stability.
3Quantity of substance
If the battery pack is designed with larger footprint to compensate for lower volumetric efficiency, then cell volume for range is improved, but vehicle size and stopping distance increase
Solution Approach 1:
By merging the battery pack structure with the vehicle body structure, the patent enables more efficient space utilization. The integrated design allows battery cells to be positioned closer to the vehicle edges and utilizes previously wasted space between the battery pack and vehicle chassis. This merging approach increases effective cell volume within the same vehicle footprint, improving range without increasing vehicle size.
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 solution enhances volumetric efficiency, reduces weight, and improves safety by forming a rigid, integral battery structure that can be easily handled and integrated into the vehicle body, while also providing impact absorption and thermal management.
Implementation Method 1
each battery cell being placed in a respective accommodating cavity and connected to adjacent walls of the respective accommodating cavity via a flowable bonding substance being inserted between the cells and the walls of the respective cavity
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present disclosure relates to an electric vehicle comprising a battery assembly (4) with at least two rows (31-34) of battery cells (39,40) attached to a battery frame structure (30). The battery frame structure has a number of accommodating cavities (35,36), arranged in a matrix, each battery cell (39,40) being placed in a respective accommodating cavity (35,36) and connected to adjacent walls (43,44,45) of the respective accommodating cavity (35,36) via a flowable bonding substance being inserted in a gap (41,42) between the cells and the walls (43,44,45) of the respective cavity.