Cylindrical Battery Pack Frame with Semi-Cylindrical Receiving Parts
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Solution Overview
Problem
Existing methods for constructing battery packs with cylindrical unit cells face challenges in maintaining structural stability and preventing internal short circuits, while also being costly and time-consuming due to the need for additional outer cases and complex assembly processes.
Innovation Solution
A frame member system comprising an upper and lower frame with semi-cylindrical battery receiving parts that allow for secure mounting of cylindrical unit cells and a protection circuit module, along with a spacer that enables efficient heat removal and simple assembly, using lightweight and heat-resistant materials like polycarbonate or ABS for the frame members and spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cylindrical unit cells are used in battery packs, then greater capacity is achieved, but maintaining the arrangement structure becomes difficult
Solution Approach 1:
The frame member is divided into multiple receiving parts, each designed to hold a specific cylindrical unit cell. This segmentation provides individual positioning for each cell, maintaining the overall arrangement structure while accommodating the cylindrical shape and maximizing capacity.
Solution Approach 2:
The frame member uses a molded structural design that flexibly adapts to the cylindrical shape of the unit cells. The receiving parts are shaped to conform to the circular cross-section of the batteries, providing stable positioning without rigid constraints that would complicate assembly.
2Stability of the object's composition
If tape or plastic coating is used to connect cylindrical unit cells, then the arrangement structure is maintained, but the strength is small and the possibility of damage is high
Solution Approach 1:
The invention extracts the weak connection function from the battery cells themselves and relocates it to the frame member. The frame member provides the structural support and positioning, while the battery cells focus on their primary function of energy storage, eliminating the need for weak tape or plastic connections.
Solution Approach 2:
The frame member acts as an intermediary structure between the cylindrical unit cells. It provides a robust framework that holds the cells in place, replacing the weak direct connections between cells with strong indirect connections through the frame structure.
3Reliability
If an outer case is used to wrap the core pack, then the protection circuit can be mounted, but the manufacturing costs and process time increase
Solution Approach 1:
The invention merges the functions of the outer case and the frame member into a single integrated structure. The frame member simultaneously provides mechanical support, positions the battery cells, and offers mounting surfaces for the protection circuit, eliminating the need for a separate outer case and reducing manufacturing complexity.
Solution Approach 2:
The frame member is designed with multi-functionality: it serves as the structural framework, the positioning mechanism for cylindrical cells, the mounting base for the protection circuit, and the overall housing replacement. This universal design reduces the total number of components and simplifies the manufacturing process.
Data Source
AI summary
Disclosed herein are a frame member including an upper frame member having one major surface to which a protection circuit module (PCM) is mounted, and a lower frame member coupled with the upper frame member, the upper and lower frame members being provided at opposite major surfaces thereof with semi-cylindrical battery receiving parts corresponding to outer surfaces of the cylindrical unit cells mounted between the upper and lower frame members, a spacer provided at opposite major surfaces of a rectangular frame with pluralities of semi-cylindrical battery receiving parts corresponding to outer surfaces of the cylindrical batteries, the battery receiving parts being partially open such that the battery receiving parts communicate with neighboring battery receiving parts on the same plane, and a battery pack including the frame member and the spacer.