Structural Battery Pack Layout for Higher Cell Packing Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs in electric vehicles and grid storage systems are costly, complex, and inefficient in terms of mass, volume, and manufacturing overhead, requiring significant structural support and additional components that increase costs and reduce packing density.
Innovation Solution
A unitary battery pack with a structural frame that integrates battery cells and supports the vehicle frame, incorporating features like dielectric sleeves, thermal management, and resin encapsulation to enhance efficiency and reduce overhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional battery packs use separate structural support frames and additional components, then structural integrity is maintained, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent combines the structural support frame and battery cell housing into a single integrated unitary battery pack structure. The frame members are directly formed as part of the battery pack enclosure, eliminating the need for separate support structures and reducing the number of parts while maintaining structural integrity.
Solution Approach 2:
The unitary battery pack structure serves multiple functions simultaneously: it provides structural support for the vehicle, houses the battery cells, and acts as part of the vehicle body structure. This multi-functionality reduces the need for additional dedicated components.
2Reliability
If battery packs include extensive structural support and additional components, then reliability is improved, but mass and volume increase
Solution Approach 1:
By merging the structural support functions into the battery pack housing itself, the patent eliminates redundant structures. The frame members are integrated into the battery pack enclosure, reducing overall mass while maintaining the structural support necessary for reliability.
3Reliability
If battery packs include extensive structural support and additional components, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent reduces manufacturing complexity by combining multiple components into a single unitary structure. The battery pack housing and structural support frame are formed as one integrated component, reducing the number of parts to manufacture, assemble, and manage.
Solution Approach 2:
The unitary battery pack is designed with frame members that are strategically positioned to provide structural support at key locations while maintaining an open architecture that simplifies manufacturing and assembly processes.
4Ease of manufacture
If battery packs use conventional configurations with separate components, then ease of manufacture is maintained, but packing density decreases
Solution Approach 1:
By integrating the structural support frame into the battery pack housing, the patent eliminates the space required for separate support structures. This allows battery cells to be packed more densely within the available volume while maintaining manufacturing simplicity through the unitary design.
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.