Expandable Battery Module Common Wall Design
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Solution Overview
Problem
Conventional battery packs face challenges in maintaining mechanical stiffness while maximizing energy density, often requiring crash beams that reduce available space and complicate assembly.
Innovation Solution
A battery pack design featuring unit battery modules with side plates that form a common wall when connected, reducing the need for additional coupling components and enhancing mechanical stiffness without separate crash beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crash beams are installed to improve mechanical stiffness, then the durability against shocks and vibrations is enhanced, but the space available to mount battery modules is reduced and energy density is lowered
Solution Approach 1:
The side plate of the battery module integrates both the structural support function (previously performed by separate crash beams) and the boundary enclosure function. By merging these functions into a single integrated side plate structure, the patent eliminates the need for separate crash beams while maintaining mechanical stiffness, thereby increasing the space available for battery modules and improving energy density.
2Strength
If crash beams are individually installed with battery modules, then mechanical stiffness is improved, but the number of coupling members increases and assembly complexity is increased
Solution Approach 1:
The side plate is designed as an integrated structural component that combines the crash beam support function with the module enclosure. This merging eliminates the need for separate coupling members between crash beams and battery modules, reducing assembly complexity and the number of parts required.
Solution Approach 2:
The side plate serves multiple functions simultaneously: it provides structural support (crash beam function), encloses the battery module (housing function), and provides mounting surfaces (coupling function). This multi-functionality reduces the overall system complexity by eliminating the need for separate components for each function.
3Strength
If crash beams are installed in the battery pack, then mechanical stiffness is improved, but unnecessary gaps are created between battery modules and crash beams reducing space utilization
Solution Approach 1:
By integrating the crash beam function into the side plate itself, the patent eliminates the gaps that would exist between separate crash beams and battery modules. The side plate forms a continuous structural boundary that maximizes space utilization while maintaining the necessary mechanical stiffness.
Data Source
AI summary
Disclosed is a battery pack, which includes a plurality of unit battery modules, each unit battery module having a plurality of battery cells accommodated in an inner space thereof, the plurality of unit battery modules being structurally connected successively in one direction; and a pack case configured to cover the plurality of unit battery modules, wherein each unit battery module has two side plates forming opposite side surfaces thereof, and wherein one of the side plates of any one of the unit battery modules and one of the side plates of another one of the unit battery modules adjacent thereto are engaged with each other to form a single common wall.