Battery Module Support Structure for High-Density Pack Integration
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Solution Overview
Problem
Conventional battery packs face challenges in maintaining high energy density and structural rigidity due to manufacturing tolerances, which lead to increased dead space and limitations in accommodating large battery modules within spatial constraints.
Innovation Solution
A battery module design that includes a support member between battery cells, with an extension portion protruding beyond the end covers, which is coupled to the pack housing, providing structural stability and allowing for efficient packing of multiple modules within a limited space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If more battery modules are disposed to increase output, then power output is improved, but dead space increases and energy density is lowered
Solution Approach 1:
The support member extends in the second direction (perpendicular to battery cell stacking) beyond the end covers, utilizing three-dimensional space efficiently. This extension allows the support member to couple with the pack housing while minimizing dead space between modules, thereby maintaining high energy density even as more modules are added to increase power output.
Solution Approach 2:
The support member serves multiple functions: it provides structural support between battery cells, extends to couple with the pack housing for rigid fixation, and optimizes space utilization. This multi-functionality allows the same component to address both structural requirements and space efficiency, preventing dead space accumulation as module count increases.
2Strength
If frame structures are added inside the case for structural rigidity, then structural rigidity is improved, but spatial restrictions increase and large battery modules cannot be disposed
Solution Approach 1:
The support member is integrated directly into the battery module structure, merging the functions of internal cell support with external pack housing coupling. This eliminates the need for separate frame structures inside the case, as the support member's extension beyond the end covers provides direct attachment points to the pack housing, achieving rigid fixation without consuming additional internal space.
Solution Approach 2:
The coupling function between battery modules and pack housing is extracted from the traditional frame structure and embodied in the support member extension. By taking out the rigid fixation requirement from the internal frame system and implementing it through the support member's external extension, the patent eliminates spatial restrictions while maintaining structural rigidity.
3Stability of the object's composition
If support member extends beyond end covers to couple with pack housing, then structural stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The support member features localized extension portions at specific locations beyond the end covers, rather than requiring uniform precision throughout the entire structure. This local quality approach concentrates manufacturing precision requirements only at the critical coupling points with the pack housing, while other portions can accommodate normal manufacturing tolerances, thereby maintaining structural stability without excessively high precision requirements.
Data Source
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AI summary
Provided is a battery module, the battery module including: a plurality of battery cells stacked in a first direction; a support member disposed between the plurality of battery cells; a module housing in which the plurality of battery cells are accommodated; and a plurality of end covers coupled to the module housing, and facing the plurality of battery cells in a second direction, perpendicular to the first direction, wherein the support member protrudes further in the second direction from the plurality of end covers.