Battery Module Support Structure for Dense Pack Rigidity
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Solution Overview
Problem
High-power, high-capacity battery packs face challenges in maintaining structural rigidity and energy density due to spatial constraints and dead spaces created by manufacturing tolerances, which affect the efficient arrangement and performance of battery modules.
Innovation Solution
Incorporating a support member between battery cell assemblies and using a modular housing structure with end covers and a pack housing that includes a bottom frame and side frames, where the support member protrudes to connect with the pack housing, enhancing structural stability and energy density by efficiently arranging battery modules in limited spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are stacked in a limited space to increase energy density, then energy density is improved, but structural rigidity deteriorates due to spatial constraints and dead spaces
Solution Approach 1:
The support member is divided into a body portion and extension portions, where the body portion is disposed between cell assemblies and the extension portions protrude to connect with pack housing. This segmentation allows the support member to provide structural reinforcement without occupying excessive space, thus maintaining energy density while improving structural rigidity.
Solution Approach 2:
The support member extends in the first direction (perpendicular to cell stacking direction) with extension portions that protrude beyond end covers. This dimensional extension allows the support member to connect with pack housing for structural reinforcement without interfering with the compact cell arrangement in the stacking direction, thereby maintaining high energy density.
2Strength
If a support member is added between cell assemblies to improve structural rigidity, then structural rigidity is improved, but device complexity increases
Solution Approach 1:
The support member serves multiple functions: it provides structural reinforcement between cell assemblies, extends to connect with pack housing for additional rigidity, and maintains cell assembly positioning. This multi-functionality allows a single component to address multiple structural requirements without proportionally increasing complexity.
Solution Approach 2:
The support member integrates the body portion for cell support and extension portions for pack housing connection into a single unified structure. This merging of functions into one component reduces the number of separate parts needed, thereby improving structural rigidity without proportionally increasing device complexity.
3Stability of the object's composition
If extension portions protrude beyond end covers to connect with pack housing, then structural stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The extension portions act as intermediaries that connect the support member (between cell assemblies) to the pack housing. This intermediary structure provides a dedicated connection interface that simplifies the assembly process and reduces precision requirements compared to direct connection between cell assemblies and pack housing.
Solution Approach 2:
The connection function between support member and pack housing is extracted into separate extension portions that protrude beyond end covers. This extraction creates dedicated connection interfaces with sufficient clearance, allowing for easier alignment and assembly while maintaining structural stability.
Data Source
AI summary
A battery module is disclosed. In some implementations, the battery module includes a plurality of cell assemblies, each cell assembly 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 extends to protrude in the first direction, relative to the plurality of end covers.