Integrated Battery Pack Bracket Layout for Lighter Cell Stack Assembly
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Solution Overview
Problem
Conventional battery packs have redundant components that hinder productivity and weight reduction due to their complex configurations, which are not optimized for efficient assembly and performance.
Innovation Solution
A simplified battery pack configuration that eliminates redundant components, featuring a pack housing with integrated fixing brackets and a support member, along with a compression member and bus bar assembly, to securely hold and connect multiple cell stacks while minimizing weight and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery packs use separate housings for battery modules and battery packs with multiple redundant components, then structural stability and component protection are improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the battery module housing and battery pack housing into a single integrated housing structure. The housing simultaneously accommodates multiple cell stacks and serves as both the module-level and pack-level enclosure, eliminating redundant housing components while maintaining structural integrity and protection functions.
Solution Approach 2:
The housing is designed to perform multiple functions: it serves as the structural enclosure for individual battery modules, the containment structure for the entire battery pack, and provides mounting surfaces for fixing brackets. This multi-functional design eliminates the need for separate housing components at different hierarchical levels.
2Strength
If conventional battery packs include multiple redundant components for structural support and fastening, then mechanical strength and assembly reliability are improved, but weight and manufacturing complexity increase
Solution Approach 1:
The fixing bracket is integrated directly into the housing structure, forming a unified component that provides both structural support and fastening functions. This integration eliminates the need for separate structural support components while maintaining mechanical strength through the combined design.
Solution Approach 2:
The integrated fixing bracket housing performs multiple functions: it provides structural support for cell stacks, serves as the fastening mechanism through integrated bracket features, and maintains overall pack integrity. This multi-functionality reduces the total component count and weight while preserving mechanical strength.
3Reliability
If conventional battery packs use complex configurations with redundant components, then component protection and structural integrity are improved, but productivity and assembly efficiency deteriorate
Solution Approach 1:
The integration of housing and fixing brackets into a single component reduces the number of assembly steps. Workers install one integrated component rather than multiple separate parts, significantly improving assembly efficiency while maintaining structural integrity through the unified design.
Solution Approach 2:
The battery pack is organized into modular cell stacks that are independently assembled and then integrated into the housing. This segmentation allows for parallel assembly of cell stacks followed by a single integration step, improving overall productivity while maintaining structural integrity.
Data Source
AI summary
A battery pack, may include: a plurality of cell stacks including a plurality of battery cells; a pack housing accommodating the plurality of cell stacks; a fixing bracket disposed between the plurality of cell stacks and the pack housing and between the plurality of cell stacks; and a fastening member fastening the fixing bracket to the pack housing, wherein the fixing bracket may be disposed to contact the plurality of battery cells on an upper side of the plurality of cell stacks.