Battery Module Cross Beam Elimination via Integrated Frame
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Solution Overview
Problem
Conventional battery packs face challenges in achieving both structural stability and high energy density due to the space constraints imposed by the cross beam used for reinforcement, which reduces space utilization in electric vehicles.
Innovation Solution
A battery module design that eliminates the cross beam by using a module frame with a top and bottom plate, barriers, and side plates to house battery submodules in a matrix form, providing structural support and allowing for dense packing without a conventional cross beam, while incorporating a module/tray connection member for securing the modules to a pack tray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cross beam is installed at the pack tray to reinforce rigidity, then the structural stability is improved, but the space utilization is reduced
Solution Approach 1:
The module frame is designed to simultaneously serve as both the housing structure for battery submodules and the cross beam for reinforcing pack tray rigidity. The module frame is coupled to the pack tray through connection members, merging the structural support function with the battery housing function into a single integrated component.
Solution Approach 2:
The module frame performs multiple functions: it houses the battery submodules, provides structural support to the pack tray by acting as a cross beam, and contributes to the overall rigidity of the battery pack. This multi-functionality eliminates the need for a separate cross beam component.
2Quantity of substance
If battery modules are densely packed to increase energy density, then the space utilization is improved, but the structural rigidity may be compromised
Solution Approach 1:
The module frame serves dual purposes by both housing the battery submodules and providing structural reinforcement to the pack tray. This integration allows dense packing of battery modules while maintaining structural rigidity through the frame's coupling to the pack tray.
Solution Approach 2:
The module frame is pre-designed with coupling structures and connection members that enable it to provide structural support before the battery modules are installed. This preliminary structural preparation ensures that rigidity is maintained even when modules are densely packed.
Data Source
AI summary
A battery module and a battery pack are disclosed. The battery module includes a module frame having a top plate and a bottom plate vertically spaced apart from each other at a predetermined interval and disposed to face each other, and at least one barrier configured to vertically partition a space between the top and bottom plates; two or more battery submodules arranged inside the module frame in a matrix form with the at least one barrier being interposed therebetween; and a left side plate and a right side plate configured to cover a left side and a right side of the module frame and a front cover and a rear cover configured to cover a front side and a rear side of the module frame.