Structural Battery Pack Layout for Dense Cells and Heat Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs face challenges in achieving high energy density and structural integrity due to compact cell placement, which leads to thermal runaway and mechanical stress, often requiring extensive insulation and isolation that reduces capacity and energy density.
Innovation Solution
The battery pack design incorporates battery cells as part of the structural support, using a longitudinal beam and side beams to facilitate load distribution, reduce insulation, and enhance heat transfer, allowing for closer cell spacing and increased volumetric energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are compactly placed to increase energy density, then volumetric energy density is improved, but thermal management becomes more difficult and structural integrity deteriorates
Solution Approach 1:
The patent combines thermal management functionality with structural support by integrating cooling channels directly into the structural beams that also provide mechanical support. This merging allows compact cell placement while maintaining effective heat removal, as the structural beams serve dual purposes of support and thermal management.
Solution Approach 2:
The structural beams are designed to perform multiple functions simultaneously: providing mechanical support for compact cell arrangement, serving as heat sinks with integrated cooling channels, and acting as part of the overall thermal management system. This multi-functionality resolves the contradiction by making the structural components actively participate in thermal management.
2Quantity of substance
If battery cells are compactly placed to increase energy density, then volumetric energy density is improved, but structural integrity deteriorates
Solution Approach 1:
The patent merges structural support and thermal management functions into integrated beams that provide both mechanical strength and cooling. These beams are positioned to support compactly arranged cells while containing internal cooling channels, allowing high cell density without compromising structural integrity.
Solution Approach 2:
The structural beams appear to be constructed from composite materials or designed as composite structures that provide both high mechanical strength for structural integrity and thermal conductivity for effective heat removal. This composite approach allows the same component to satisfy both structural and thermal management requirements.
3Reliability
If extensive insulation and isolation are used to prevent thermal runaway, then safety is improved, but volumetric energy density deteriorates
Solution Approach 1:
The patent converts the potential harm of heat generation into a benefit by using the structural beams as active heat sinks with integrated cooling channels. Instead of isolating cells with insulation, the system actively removes heat through the beams, turning the thermal challenge into a safety advantage while maintaining compact cell placement.
Solution Approach 2:
The structural beams with cooling channels serve as intermediaries between the battery cells and the external environment. Rather than direct insulation or isolation, the beams mediate heat transfer from the cells to the cooling system, providing safety through active thermal management rather than passive insulation.
4Reliability
If extensive insulation and isolation are used to prevent thermal runaway, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges safety and thermal management functions into the structural beams themselves, eliminating the need for separate insulation layers and isolation components. The beams with integrated cooling channels provide safety through active cooling while maintaining structural support, thereby reducing overall system complexity.
Solution Approach 2:
The structural beams are designed as multi-functional components that simultaneously provide mechanical support and active thermal management for safety. This universality eliminates the need for separate insulation and cooling systems, reducing device complexity while maintaining or improving safety performance.
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 increases volumetric energy density and structural integrity by utilizing battery cells as structural components, reducing insulation and allowing for a more compact and robust battery pack with improved heat management and longer cycle life.
Implementation Method 1
The base may be a heat exchanger, and the base may define fluid channels extending orthogonally to the longitudinal beam
Implementation Method 2
a plurality of battery cells disposed adjacent the longitudinal beam
Data Source
AI summary
Battery packs according to some embodiments of the present technology may include a longitudinal beam. The packs may include a plurality of battery cells disposed adjacent the longitudinal beam. Each battery cell may be characterized by a first surface, and a second surface opposite the first surface. Each battery cell may be characterized by a third surface extending vertically between the first surface and the second surface. The first surface may face the longitudinal beam, and battery terminals may extend from the third surface. Each battery cell may be characterized by a fourth surface opposite the third surface. The packs may include a lid coupled with the first surface of each battery cell of the plurality of battery cells. The packs may include a base coupled with the second surface of each battery cell of the plurality of battery cells.