Structural Battery Pack Assembly for Lower EV Pack Weight
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Solution Overview
Problem
Existing electric vehicle battery packs are costly, complex, and inefficient in terms of mass, volume, and manufacturing overhead, requiring significant structural support and additional components that increase weight and reduce energy density.
Innovation Solution
A unitary battery pack with a structural frame that integrates battery cells and supports the vehicle frame, incorporating features like dielectric cell sleeves, laser-welded interconnects, and a resin structure for thermal management and impact absorption, reducing the need for additional support structures and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery packs use separate structural support frames and additional components, then structural strength and support are improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the structural support frame and battery cell holders into a single integrated unitary battery pack structure. The frame itself serves as both the structural support and the mounting structure for battery cells, eliminating the need for separate support components and reducing assembly complexity while maintaining required structural strength.
Solution Approach 2:
The unitary battery pack structure performs multiple functions simultaneously: it provides structural support for the vehicle, serves as the mounting framework for battery cells, and acts as the protective enclosure. This multi-functionality eliminates redundant components and simplifies the overall assembly.
2Stability of the object's composition
If traditional battery packs include additional support structures and components, then structural stability is improved, but weight increases
Solution Approach 1:
By combining the structural support frame and battery cell holders into one unitary structure, the patent eliminates the weight of separate support components while maintaining structural stability through the integrated design that provides necessary support and protection.
3Ease of manufacture
If traditional battery packs use separate components and assemblies, then ease of manufacturing individual parts is improved, but manufacturing overhead and cost increase
Solution Approach 1:
The unitary battery pack structure can be manufactured as a single integrated component or pre-assembled module, reducing the number of separate parts that need to be manufactured, stored, and assembled. This reduces manufacturing overhead and complexity while maintaining ease of production through standardized processes.
4Reliability
If traditional battery packs include redundant components, then reliability and protection are improved, but energy density decreases
Solution Approach 1:
The integrated unitary structure provides necessary protection and support functions with minimal material, maximizing the proportion of volume and mass dedicated to energy-storing battery cells. The structure provides adequate reliability through its integrated design without the weight and volume penalty of redundant separate components.
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 reduces material and manufacturing costs, minimizes weight, and increases energy density by simplifying assembly and eliminating redundant components, while providing effective thermal management and impact protection.
Implementation Method 1
The bottom layer is designed so that it can absorb and distribute impact energy from below, mitigating potential damage sensitive battery materials or breach of the sealed battery pack enclosure
Implementation Method 2
laser-welded interconnects
Implementation Method 3
dielectric cell sleeves
Implementation Method 4
a resin structure for thermal management
Data Source
AI summary
An integrated, unitary battery pack may be formed and used as part of the structural support for a vehicle frame. The unitary battery pack includes arrays cells having all positive and negative electrical terminals aligned in-plane on a common face of the product assembly. The unitary battery pack includes cooling components for passively or actively cooling the cell arrays. The unitary battery pack is encased in a potting material that allows that forms part of the structure support for the unitary battery pack. The unitary batter pack may be integrated into the vehicle with or without additional support structures.