Hexagonal Structural Battery Pack Layout for Lower Pack Mass
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Solution Overview
Problem
Battery packs in electric vehicles consume significant space and weight due to protective housings, necessitating a reduction in weight while maintaining protection.
Innovation Solution
A structural battery pack design incorporating a hexagon-patterned arrangement of cylindrical battery cells with integrated interconnect boards and a frame system that provides structural support, eliminating traditional module housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional protective pack housing and module housings are used, then battery cells are protected from damage, but significant space and weight are consumed
Solution Approach 1:
The patent merges the protective housing function with the structural support function by integrating the outer frame to simultaneously provide mechanical protection for battery cells and structural support for the entire battery pack, eliminating the need for separate protective housings and reducing overall weight
Solution Approach 2:
The outer frame serves multiple functions: it protects battery cells from damage, provides structural support for the battery pack, and enables force distribution during impact events, replacing multiple dedicated components with a single multi-functional structure
2Reliability
If traditional module housings are used, then battery cells are protected, but weight increases significantly
Solution Approach 1:
The patent eliminates separate module housings by integrating the protective function into the outer frame structure, which simultaneously provides mechanical protection and structural support, thereby reducing the total weight of the battery pack while maintaining cell protection
3Reliability
If protective housings are designed to establish specified protection level, then battery cells are protected from damage, but considerable space is consumed
Solution Approach 1:
The patent combines the protective housing and structural support functions into a single integrated outer frame, eliminating the need for separate protective housings and module housings, thereby reducing the overall volume occupied by protective structures while maintaining adequate protection levels
Data Source
AI summary
A structural battery pack includes a bottom cover, a bottom cell carrier, multiple battery cells, a cooling ribbon, a top cell carrier, and a top cover. The bottom cover has a rectangular shape that defines a longitudinal direction and a lateral direction. The bottom cell carrier is coupled to the bottom cover, and defines multiple bottom holders. The bottom holders are arranged in a hexagon pattern that defines multiple rows in the longitudinal direction and multiple columns in the lateral direction. The top cell carrier is coupled to the top cover, defines multiple top holders, and includes an interconnect board that interconnects the battery cells. The top holders are arranged in the hexagon pattern. The battery cells are installed in the bottom cell carrier and the top cell carrier. Each battery cell has a cylindrical shape. The cooling ribbon is installed between the battery cells along the rows.