Vehicle Energy Unit Cells Integrated Into Load-Bearing Structure

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Solution Overview

Problem

Conventional manufacturing techniques for vehicles result in large, separate energy storage enclosures that do not contribute to vehicle stiffness or strength, increasing mass and reducing efficiency and performance, while additive manufacturing methods face challenges in joining large components and integrating energy storage systems effectively.

Innovation Solution

Utilizing additive manufacturing techniques like DMD and PBF to integrate energy unit cells directly into the primary vehicle structure, optimizing enclosure and connection paths, and employing alternative joining methods such as adhesive bonding to create complex, functional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional manufacturing techniques are used to create separate energy storage enclosures, then the enclosures can be manufactured using traditional methods, but the vehicle mass increases and efficiency decreases

Engineering Contradiction:

Improvemanufacturing methodVSAvoidvehicle mass

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent combines the energy storage enclosure with the primary vehicle structure into a single integrated component. The enclosure is designed to share load paths with the vehicle frame, merging two previously separate functions (structural support and energy storage containment) into one unified structure, thereby eliminating redundant mass while maintaining both structural integrity and energy storage capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated enclosure serves multiple functions simultaneously: it acts as both the primary vehicle structure for load-bearing and as the containment structure for energy storage devices. This multi-functional design eliminates the need for separate structural frames and energy storage housings, reducing overall vehicle mass while improving structural efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If conventional manufacturing techniques are used for energy storage enclosures, then traditional manufacturing processes can be employed, but the enclosures do not contribute to vehicle stiffness or strength

Engineering Contradiction:

Improvemanufacturing processVSAvoidvehicle stiffness and strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent merges the energy storage enclosure with the primary vehicle structure so that the enclosure becomes an integral load-bearing component. The design ensures that the enclosure shares load paths with the vehicle frame, allowing it to contribute to both energy storage containment and structural stiffness and strength simultaneously

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If additive manufacturing is used to create large components, then complex functional components can be manufactured, but joining challenges and integration difficulties arise

Engineering Contradiction:

Improvecomponent complexity and functionalityVSAvoidjoining and integration

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges the energy storage enclosure design with the primary vehicle structure topology optimization, creating a unified design that is manufactured as a single integrated component using additive manufacturing. This approach eliminates the need for joining separate enclosure and frame components, resolving the joining challenges inherent in conventional manufacturing approaches

Inventive Principle:

Principle #5Merging (Combining)

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 approach reduces vehicle mass by integrating energy storage systems into the primary structure, enhancing stiffness and strength, and improving overall vehicle efficiency and performance.

Implementation Method 1

Direct Metal Deposition (DMD) is an AM technology that uses a laser to melt metallic powder and thereby transform it into a solid metal object

Methodology Applied

Scientific EffectLaser melting: Laser

Implementation Method 2

electron beam melting, a powder is placed under a vacuum and a high-powered electron beam is utilized to generate energy needed for high melting capacity and high productivity. The powder is fused together using the energy generated by the electron beam

Methodology Applied

Scientific EffectElectron beam: Electron Beam

Data Source

PatentUS12459377B2Energy unit cells for primary vehicle structure

Publication Date: 2025.11.04 DIVERGENT TECHNOLOGIES INC

AI summary

Methods and apparatuses for energy unit cells for primary structures are described. The method comprises obtaining enclosure criteria of an enclosure space, wherein the enclosure space is configured to contain an energy storage device. The method further comprises obtaining a load case of a primary structure of a vehicle. The method further comprises determining a primary structure design based on the enclosure criteria and the load case, where the primary structure design incorporates the enclosure space.