Battery Module Support Structure for High-Density Pack Layout

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Solution Overview

Problem

Battery packs face challenges in maintaining structural rigidity and high energy density due to manufacturing tolerances and spatial constraints, leading to increased dead space and decreased energy efficiency as more battery modules are added.

Innovation Solution

Incorporating a support member between battery cell assemblies within a battery module and pack housing, which protrudes to provide structural support and stability, allowing for efficient packing of large modules in limited spaces while maintaining energy density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple battery modules are arranged to increase power capacity, then power output is improved, but dead space increases and energy density decreases

Engineering Contradiction:

Improvepower outputVSAvoidenergy density

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

The support member is integrated into the battery module structure itself, merging the support function with the module housing. This eliminates the need for separate support structures in the battery pack, reducing dead space and improving energy density while maintaining the ability to arrange multiple modules for high power output

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support member serves multiple functions: it provides structural support between cell assemblies, acts as a mounting structure for end covers, and enables secure installation in the battery pack. This multi-functionality reduces the number of separate components needed, minimizing dead space and improving energy density

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If frame structures are added inside the case to maintain structural rigidity, then structural stability is improved, but dead space increases and energy density decreases

Engineering Contradiction:

Improvestructural rigidityVSAvoidenergy density

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support function is extracted from the battery pack level and moved to the battery module level. By incorporating the support member within each module, the patent eliminates the need for additional frame structures at the pack level, reducing dead space while maintaining structural rigidity

Inventive Principle:

Principle #2Taking out (Extraction)

3Quantity of substance

If large battery modules are disposed to increase capacity, then energy storage capacity is improved, but spatial constraints make arrangement difficult

Engineering Contradiction:

Improveenergy storage capacityVSAvoidarrangement ease

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The battery system is segmented into modular units with standardized support members. This segmentation allows large capacity modules to be designed with integrated support structures that facilitate easy arrangement and assembly within the battery pack, overcoming spatial constraints through modular design

Inventive Principle:

Principle #1Segmentation

4Strength

If support members are added between cell assemblies to improve structural stability, then structural rigidity is improved, but device complexity increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4386946A1Battery module and battery pack including the same

Publication Date: 2024.06.19 SK ON CO LTD

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AI summary

A battery module is disclosed. In some implementations, the battery module includes a plurality of cell assemblies respectively including a plurality of battery cells stacked in a first direction, a support member disposed between the plurality of cell assemblies, and a plurality of end covers facing at least one of the plurality of cell assemblies in the first direction, wherein the support member protrudes in the first direction, relative to the plurality of end covers.