Battery Module Side Plate Structure for Long-Pack Rigidity
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Solution Overview
Problem
Existing battery packs face challenges in achieving enhanced structural rigidity for the frame portion of battery modules, which is crucial for supporting battery cells and maintaining durability, especially in long battery modules.
Innovation Solution
The battery pack incorporates a frame portion with strengthened structural rigidity through the use of roll-formed side plates made of stainless steel or steel, which are bent to form folded portions and connected to the frame via fastening members, thereby improving the rigidity and durability of the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flange thickness is increased to provide sufficient rigidity for fixing the long battery module, then the structural rigidity is improved, but the space efficiency is reduced due to increased thickness
Solution Approach 1:
The flange is formed with a curved surface instead of a flat surface, creating a拱形 (arch) structure that naturally distributes and disperses stress. This curvature provides enhanced structural rigidity and load-bearing capacity without increasing the thickness of the flange, thereby resolving the contradiction between strength and volume.
2Strength
If traditional welding methods are used to join the flange to the battery module, then the connection strength is achieved, but the manufacturing complexity and facility investment costs increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using fastening members that pass through through-holes in the flange and battery module. This substitution eliminates the need for complex welding facilities and procedures while achieving sufficient connection strength through mechanical interlocking.
3Power
If the battery module length is increased to meet high-output requirements, then the power capacity is improved, but the structural rigidity and stability deteriorate
Solution Approach 1:
The curved surface of the flange creates an arch structure that inherently resists bending and maintains structural integrity. This allows the battery module to be extended in length to increase power capacity while the curved flange maintains structural rigidity and stability at the connection points with the battery pack frame.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the structural rigidity of the battery pack, improves space efficiency by reducing thickness, and minimizes facility investment costs by utilizing roll forming for side plate manufacturing.
Implementation Method 1
The folded portion may be welded to the surface of the side plate
Data Source
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AI summary
A battery pack includes a frame portion forming an accommodation space, a plurality of battery modules positioned in the accommodation space of the frame portion, a lower cover that covers a lower portion of the frame portion, and an upper cover that covers an upper portion of the frame portion. Each of the battery modules includes a plurality of battery cells, a plurality of side plates that include bent portions that are coupled to the frame portion and support side surfaces of the battery cells, and a plurality of end plates that connect ends of each of the side plates to each other.