Side Reinforcement Frame for Battery Module Impact Protection

Solution Overview

Problem

Existing power supply devices lack sufficient impact resistance and weight optimization, particularly in applications requiring high power and long-term operation, such as electric vehicles and hybrid vehicles.

Innovation Solution

A power supply device with a side reinforcement frame surrounding a refrigerant pipe and battery modules, utilizing a composite material for improved impact resistance and reduced weight, featuring a module housing with a main housing, first and second plates, and a side reinforcement frame that extends across battery modules for enhanced structural integrity and cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a power supply device uses a pack type including multiple batteries to achieve high power and long-term operation, then the output voltage and output current are increased, but the device becomes more susceptible to external impacts and weight increases

Engineering Contradiction:

Improveoutput voltageVSAvoidimpact resistance

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The housing is constructed using a composite material comprising a resin matrix and glass fibers dispersed within it. This composite structure provides enhanced mechanical strength and impact resistance while maintaining a relatively low weight, thus protecting the multiple battery cells from external impacts without significantly increasing the overall device weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing features a curved outer surface with rounded corners and edges, replacing sharp angular transitions. This curved geometry distributes impact forces more effectively across the housing structure, reducing stress concentration points and improving the device's resistance to external impacts.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Power

If a power supply device uses a pack type including multiple batteries to achieve high power and long-term operation, then the output current is increased, but the device becomes more susceptible to external impacts and weight increases

Engineering Contradiction:

Improveoutput currentVSAvoiddevice weight

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

The housing is constructed using a composite material comprising a resin matrix and glass fibers dispersed within it. This composite structure provides enhanced mechanical strength and impact resistance while maintaining a relatively low weight, thus protecting the multiple battery cells from external impacts without significantly increasing the overall device weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing is designed as a thin-walled structure with optimized wall thickness distribution, providing sufficient mechanical protection while minimizing material usage and overall device weight. The curved geometry enhances structural efficiency, allowing thinner walls to achieve the same protective function.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If existing power supply devices use conventional housing structures, then manufacturing is simpler, but impact resistance is insufficient

Engineering Contradiction:

Improvehousing manufacturingVSAvoidimpact resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The housing is constructed using a composite material comprising a resin matrix and glass fibers dispersed within it. This composite structure provides enhanced mechanical strength and impact resistance while maintaining a relatively low weight, thus protecting the multiple battery cells from external impacts without significantly increasing the overall device weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing features a curved outer surface with rounded corners and edges, replacing sharp angular transitions. This curved geometry distributes impact forces more effectively across the housing structure, reducing stress concentration points and improving the device's resistance to external impacts.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

The solution provides improved impact resistance and reduced weight, ensuring reliable operation and efficient cooling of battery modules in high-power applications.

Implementation Method 1

a refrigerant pipe connected to a cooling passage of the at least one battery module

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12537244B2Power supply device having side reinforcement frame

Publication Date: 2026.01.27 SAMSUNG SDI CO LTD

AI summary

A power supply device includes: a power supply unit including at least one battery module; and a side reinforcement frame on a side surface of the power supply unit and surrounding a refrigerant pipe connected to a cooling passage of the at least one battery module.