Tiered Battery Pack Layout for Integrated Power Module Packaging
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Solution Overview
Problem
Conventional battery systems face challenges in accommodating battery cells and associated components within reduced device sizes due to spatial constraints, particularly in devices with oblong volumes where lateral dimensions exceed depth dimensions, limiting the feasibility of conventional power modules.
Innovation Solution
A battery configuration with a tiered profile and recessed ledges allows for the integration of a power control module within the battery's defined volume by utilizing lateral space, featuring a module seated on a base with terraces and spacers to isolate electrode terminals, and using a rigid housing to maintain the module's dimensions within the battery's envelope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional battery systems are used in devices with reduced size, then device size is reduced, but available space for battery cells and associated system materials is limited
Solution Approach 1:
The battery base is designed with a tiered profile featuring multiple terraces at different heights, transforming the conventional flat battery bottom into a three-dimensional stepped structure. This dimensional change allows the power module to be positioned on a higher terrace while battery cells occupy lower regions, effectively utilizing vertical space within the battery envelope and accommodating all components within reduced device dimensions.
Solution Approach 2:
The battery base is segmented into multiple terraces with different elevation levels, creating distinct zones for different components. The power module is positioned on a first terrace while battery cells are arranged in lower regions, with recessed ledges providing separation and structural support. This segmentation allows optimal spatial arrangement of components within constrained volume.
2Adaptability or versatility
If the battery base is designed with a tiered profile to accommodate a power module, then component integration is improved, but manufacturing complexity increases
Solution Approach 1:
The tiered battery base is integrated as a single structural component that simultaneously provides mechanical support for battery cells, positioning platform for the power module, and structural framework. The recessed ledges and terraces are formed as inherent features of the base rather than separate additions, reducing part count while achieving multi-functional integration.
Data Source
AI summary
Battery systems according to embodiments of the present technology may include a battery including a lid that defines lateral dimensions of the battery and a base. The base may define an internal volume of the battery between an interior surface of the lid and an interior surface of the base. The base may be coupled with the lid to define a flange extending about lateral edges of the battery. The base may define a tiered profile along an exterior surface of the battery towards a first lateral edge of the battery. The tiered profile may include a first tier defining a depth of the battery, a second tier defining a first terrace proximate the flange along an intersection of the first lateral edge of the battery and a second lateral edge of the battery, and a third tier extending inward from the first lateral edge of the battery and extending between the first terrace and the second terrace. A battery may also include a module seated on the exterior surface of the base of the battery along the third tier, and between the first terrace and the second terrace.