Battery Module Notch Layout for Crossbeam-Spanning Pack Assembly
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Solution Overview
Problem
Existing battery packs face challenges with low internal volume utilization and complex assembly due to the small size and large number of battery modules, which results in reduced mounting space for cells and increased mechanical connections.
Innovation Solution
A battery module design featuring a plurality of cells arranged in an accommodating area defined by end and side plates, with avoidance notches in the side plates to bypass crossbeams or longitudinal beams in the lower casing, allowing for increased module size and reduced number of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the battery pack uses a large number of small battery modules, then the mounting flexibility increases, but the internal volume utilization decreases and assembly complexity increases
Solution Approach 1:
The battery module is segmented into multiple battery cells arranged in series within a single module structure. This segmentation allows the module to function as both a structural unit and an electrical unit, improving volume utilization while maintaining mounting flexibility through the modular design of the entire battery pack system.
Solution Approach 2:
Multiple battery cells are merged into a single battery module structure with unified end plates and side plates. This merging reduces the number of separate modules needed, increases internal volume utilization, and simplifies assembly while the module itself can be mounted flexibly in different configurations within the battery pack.
2Device complexity
If the battery module size is increased, then the number of modules decreases simplifying assembly, but the mounting space requirements increase
Solution Approach 1:
The battery module utilizes three-dimensional space efficiently by arranging cells in multiple layers and directions within the module. The side plate with avoidance notch design allows the module to mount around structural beams in the battery pack, effectively using vertical and lateral dimensions to reduce the number of modules needed while maintaining compact footprint.
3Adaptability or versatility
If the battery module design includes avoidance notches for crossbeams, then the mounting adaptability improves, but the structural complexity of the module increases
Solution Approach 1:
The avoidance notch is implemented as a localized feature on the side plate rather than a complex overall structural design. This local modification allows the module to adapt to battery pack structural beams while maintaining simple global module geometry and cell arrangement, minimizing the increase in structural complexity.
Data Source
AI summary
A battery module includes a plurality of cells, an end plate, and a side plate. The end plate and the side plate define an accommodating area, and the plurality of cells are sequentially arranged in the accommodating area. The side plate is provided with an avoidance notch configured to avoid a crossbeam or longitudinal beam of a lower casing, and the cells are arranged to avoid a position in the accommodating area corresponding to the avoidance notch, so that the battery module is mounted across the crossbeam or the longitudinal beam of the lower casing.