Power Battery Module 3D Fixing via Baffle and Boss
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Solution Overview
Problem
Conventional power battery modules for vehicles are not securely fixed in all three dimensions, leading to reduced reliability and safety due to loosening under directional shocks, and they also contribute to increased volume and weight of the vehicle.
Innovation Solution
A power battery module design featuring an upper and lower case with inner configurations, including baffle plates and bosses, securely positions the battery pack in X, Y, and Z axes, using insulating plastic materials with mechanical strength and corrosion resistance, and incorporates sealing members and strengthening ribs for enhanced stability and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional baffle plate and pull rod structure is used, then the battery module can be assembled, but the battery pack is not firmly secured in the Y-axis direction leading to reduced reliability
Solution Approach 1:
The fixing structure is divided into multiple functional components: upper case with first fixing components, lower case with second fixing components, and baffle plates with third fixing components. Each segment handles specific directional fixation (X-axis, Y-axis, Z-axis respectively), allowing the battery pack to be securely fixed in all three dimensions through coordinated action of segmented fixing elements.
Solution Approach 2:
The invention transitions from conventional two-dimensional fixing (X-axis and Z-axis only) to three-dimensional fixing by adding Y-axis fixation capability through baffle plates with third fixing components. This dimensional enhancement ensures the battery pack cannot loosen in any direction, significantly improving reliability while maintaining structural simplicity.
2Reliability
If conventional power battery module structure is used, then the battery module can function, but the volume and weight of the vehicle are increased
Solution Approach 1:
The upper case, lower case, and baffle plates are merged into an integrated fixing system where multiple fixing components work together as a unified structure. This merging eliminates the need for separate external fixing mechanisms, reducing overall vehicle weight while maintaining enhanced three-dimensional securing capability for improved reliability.
Solution Approach 2:
The cases and baffle plates are designed as thin-walled structural components that provide sufficient mechanical strength for three-dimensional fixation while minimizing material usage. This approach reduces the weight of the fixing structure itself, contributing to overall vehicle weight reduction without compromising safety and reliability.
3Reliability
If conventional power battery module structure is used, then the battery module can function, but the volume of the vehicle is increased
Solution Approach 1:
The fixing components are nested within the boundaries of the upper and lower cases. The baffle plates with third fixing components are positioned inside the case structure, and all fixing elements are integrated within the overall module envelope. This nesting approach ensures three-dimensional securing capability without adding external protrusions, minimizing the volume occupied by the battery module in the vehicle.
Data Source
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AI summary
A power battery module (100) includes a battery pack (9), an upper case (6), a lower case (7) matched with the upper case (6), and at least one baffle plate (8) longitudinally disposed at a lateral side of the battery pack (9) between the upper case (6) and the lower case (7). At least one projection (76) is provided on at least one of the inner surface of the upper case (6) and the inner surface of the lower case (7). The upper case (6) and the lower case (7) fix the battery pack (9) in a first direction, the baffle plate (8) fixes the battery pack (9) in a second direction, the projection (76) fixes the battery pack (9) in a third direction, and the first direction, the second direction and the third direction are mutually orthogonal. The power battery module (10) achieves stable three-dimensional fixing with simplified assembly process.