Battery Housing Reinforcement With Overlapped Compressor Layout
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Solution Overview
Problem
Conventional power supply systems face challenges in enhancing the strength of the housing to protect batteries and cooling mechanisms from external impacts without increasing the size or weight, which is particularly problematic for systems mounted on moving vehicles.
Innovation Solution
A power supply system design that incorporates a strength member extending between the side walls of the housing to reinforce it, with the compressor positioned to overlap the strength member in the upright direction, allowing for improved structural integrity without enlarging the system's footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of plate material that forms the housing is increased to increase the strength of the housing, then the strength is improved, but the weight and manufacturing cost are increased
Solution Approach 1:
The housing strength enhancement is segmented into two parts: the base plate material and additional strength members. Instead of uniformly increasing plate thickness throughout, the strength members are selectively added only where structural reinforcement is needed, thereby improving strength without proportionally increasing overall weight.
Solution Approach 2:
The housing structure combines different materials or material configurations - the base plate material combined with strength members - to achieve superior strength-to-weight ratio compared to using a single thick plate material throughout.
2Strength
If a strength member is provided in the housing to increase the strength of the housing, then the strength is improved, but the manufacturing cost is increased
Solution Approach 1:
The manufacturing process is segmented into stages where strength members are added only to specific locations requiring reinforcement. This selective approach reduces material costs and assembly complexity compared to manufacturing an entirely thicker housing structure.
Solution Approach 2:
Strength members are provided only at specific locations within the housing where structural reinforcement is needed, rather than uniformly throughout. This local quality approach optimizes material usage and reduces manufacturing cost while achieving the required strength.
3Strength
If a strength member is mounted to the housing to increase the strength of the housing, then the strength is improved, but the size of the housing is enlarged
Solution Approach 1:
The strength members are nested within the existing housing structure, utilizing the internal space of the housing rather than adding external protrusions. This allows strength enhancement without significantly increasing the external dimensions or volume of the housing.
Solution Approach 2:
Instead of increasing housing volume by adding external strength elements, the strength members are positioned in the vertical dimension (upright direction) within the existing footprint, thereby reinforcing the housing without enlarging its horizontal placement space.
4Device complexity
If the compressor is positioned separately from the strength member, then the piping configuration is simplified, but the space for placement of the power supply system is enlarged
Solution Approach 1:
The compressor is merged with the strength member by positioning the compressor on the strength member. This combination serves dual purposes: the strength member provides structural reinforcement and simultaneously serves as a mounting platform for the compressor, thereby reducing overall placement space without significantly complicating piping.
Solution Approach 2:
The strength member is given multiple functions: it provides structural reinforcement to the housing and simultaneously serves as a mounting base for the compressor. This multi-functionality reduces the total number of separate components and optimizes space utilization.
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 configuration enhances the housing's strength while maintaining a compact size, reducing the risk of damage from external impacts and optimizing the placement space, while also ensuring uniform cooling efficiency and simplified piping configurations.
Implementation Method 1
a cooling portion through which a refrigerant for cooling the plurality of the batteries flows
Implementation Method 2
the batteries on the cooling member are cooled via the refrigerant that is pumped by the compressor
Implementation Method 3
a compressor configured to pump the refrigerant to the cooling portion
Data Source
AI summary
A power supply system includes a plurality of batteries, a cooling portion through which a refrigerant for cooling the plurality of the batteries flows, a housing that has a bottom plate, a top plate, and side walls, the housing accommodating the plurality of the batteries and the cooling portion, and a compressor configured to pump the refrigerant to the cooling portion. In the housing, a strength member that extends in a direction in which the side walls face each other and reinforces the housing is mounted on the bottom plate or the top plate. The compressor is disposed in a position in which the compressor and the strength member are overlapped in the upright direction of the side walls.