Rack-Integrated Battery Enclosure for Stable Module Stacking
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Solution Overview
Problem
Existing energy storage systems face challenges in ensuring structural safety, particularly in the stacking and support of battery modules within enclosures.
Innovation Solution
The proposed energy storage system incorporates a rack-integrated enclosure with a shelf supporter and horizontal supporter system, providing integral support to the enclosure and rack parts, and utilizing a coupler to securely connect the enclosure and rack brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are stacked vertically on a rack with inclined bottom surfaces, then energy storage capacity is increased, but structural stability and safety are compromised
Solution Approach 1:
The rack is divided into multiple shelf supporters (front, center, rear) spaced apart in the front-rear direction, with each shelf supporter providing independent support. The shelves are segmented into left and right shelves spaced apart in the left-right direction, creating a distributed support structure that enhances stability while accommodating multiple battery modules.
Solution Approach 2:
The patent transitions from a simple vertical stacking arrangement to a three-dimensional support structure with shelves extending in the left-right direction and shelf supporters distributed in the front-rear direction. This multi-dimensional arrangement provides comprehensive support and prevents distortion in all directions, resolving the stability issue while maintaining high energy storage capacity.
2Reliability
If the rack and enclosure are integrated with multiple support components, then structural safety is improved, but device complexity increases
Solution Approach 1:
The rack part is disposed integrally in the enclosure part, merging the rack and enclosure into a single integrated structure. The shelf supporters extend from the base to the horizontal supporter, combining vertical and horizontal support functions into unified components, thereby enhancing structural safety while avoiding the complexity of separate assembly systems.
Solution Approach 2:
The shelf supporters serve multiple functions: they provide vertical support from the base, connect to the horizontal supporter, and support the shelves in the left-right direction. The horizontal supporter connects multiple shelf supporters together, providing both structural reinforcement and alignment. This multi-functionality reduces the need for additional specialized components.
3Reliability
If the enclosure and rack are connected with brackets and couplers, then assembly safety is improved, but manufacturing complexity increases
Solution Approach 1:
The enclosure bracket protrudes downward from the top plate of the enclosure, and the rack bracket protrudes upward from the upper plate of the rack, with connection holes pre-positioned on these brackets. The coupler is designed with matching upper and lower fastening holes that align with the brackets, enabling straightforward assembly without complex alignment procedures. This preliminary positioning of connection elements simplifies the manufacturing and assembly process while ensuring safe and reliable connection.
Data Source
AI summary
An energy storage system may comprise: a plurality of battery modules; and a rack-integrated enclosure within which the plurality of battery modules are accommodated, wherein the rack-integrated enclosure comprises an enclosure part forming the external appearance and having an inner space in which a plurality of batteries are accommodated, and a rack part formed integrally with the enclosure part, and the rack part comprises: a plurality of shelf supporters vertically arranged across the space and spaced apart from each other in the forward-and-backward direction; a plurality of shelfs arranged on the shelf supporters to be vertically spaced apart from each other; and horizontal supporters connecting the plurality of shelf supporters to each other.