Battery Module Limiting Plate Coupling for Compact Pack Strength
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Solution Overview
Problem
Existing battery packs with multiple columns and series designs face insufficient connection strength between modules due to reduced mechanical components and limited mount points, leading to structural weakness and reliability issues, especially in compact designs.
Innovation Solution
A battery pack design featuring a module assembly with end plates and limiting plates, where first and second inserting and receiving portions with tapered configurations allow for secure coupling of battery modules, and a connecting member enhances stability between modules and the pack case, improving connection strength and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of mechanical components and mechanical locks is reduced to lower cost, then the cost decreases, but the connection strength between modules becomes insufficient
Solution Approach 1:
The connection structure is divided into multiple insertion portions distributed across the end plates and limiting plates. Instead of using a single complex mechanical lock, multiple simpler insertion portions are arranged to collectively provide the necessary connection strength, thereby reducing overall component complexity while maintaining structural integrity.
Solution Approach 2:
The limiting plates are integrated with the end plates through the insertion portions to form a unified connection system. This merging of components eliminates the need for separate mechanical locks and fasteners, reducing the number of parts while ensuring strong module connections through the combined structural action of the plates and insertion features.
2Quantity of substance
If the battery pack design uses multiple columns and series configuration to increase energy density, then the energy density increases, but the connection strength between modules becomes insufficient due to limited mount points
Solution Approach 1:
The connection system extends beyond traditional single-point mounting by utilizing the limiting plates that span across multiple modules. The insertion portions are distributed in both the length and width directions, creating a two-dimensional connection network that strengthens the multi-column configuration without requiring additional mount points on the battery pack housing.
Solution Approach 2:
The end plates and limiting plates serve multiple functions: they provide structural support for the battery cores, enable mechanical connection between adjacent modules through the insertion portions, and distribute forces uniformly across the module assembly. This multi-functionality allows the same components to address both energy density requirements and connection strength needs.
3Device complexity
If the mechanical components are reduced with box design, then the device complexity decreases, but the overall strength of the battery pack becomes insufficient
Solution Approach 1:
The limiting plates are integrated with the end plates through the insertion portions to form a unified connection system. This merging of components eliminates the need for separate mechanical locks and fasteners, reducing the number of parts while ensuring strong module connections through the combined structural action of the plates and insertion features.
Solution Approach 2:
The insertion portions are designed with tapered configurations that provide gradual engagement and uniform force distribution. The tapered geometry allows for smooth assembly while maintaining strong connection, eliminating the need for complex mechanical locking mechanisms and reducing overall device complexity.
Data Source
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AI summary
The present disclosure relates to a battery pack comprising: a module assembly comprising two or more battery modules, wherein each of the battery modules comprises a battery core and an end plate, a plurality of battery cores are arranged side by side along a length direction of the battery pack, the end plate is located on at least one side of the plurality of battery cores in the length direction, and the two or more battery modules are arranged side by side along a width direction of the battery pack; and a limiting plate disposed on at least one side of the module assembly in the length direction and correspondingly to the end plate, wherein the limiting plate comprises an inner side surface towards the end plate, two or more first inserting and receiving portions are provided on the inner side surface to correspond to two or more end plates respectively, a second inserting and receiving portion is provided on the surface of the end plate towards the limiting plate to correspond to one of the first inserting and receiving portions, and the two or more battery modules are coupled with the limiting plate via one of the first inserting and receiving portions and the second inserting and receiving portion respectively. The limiting plate can fix the plurality of battery modules between the limiting plate and the side wall of the battery pack case, thereby improving the connection strength between the plurality of battery modules in the battery pack.