Battery Pack Housing Beam Layout for Higher Space Utilization
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Solution Overview
Problem
Traditional battery packs have complex assembly processes, high weight, and low space utilization, leading to increased manpower and production costs, while the structural components reduce the internal space and energy density.
Innovation Solution
A battery pack design utilizing electrode core strings encapsulated in an encapsulation film, with structural beams between top and bottom plates forming an 'L'-shaped structure, enhancing space utilization, reducing weight, and improving energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional battery module assembly method is used with side plates and end plates connected by bolts or welding, then the battery set is fixed securely, but the assembly process becomes troublesome and complex, increasing manpower and production costs
Solution Approach 1:
The patent combines the battery set fixation function with the housing structure itself. The housing includes a body and a cover that enclose and secure the battery set, eliminating the need for separate side plates, end plates, and fastening components. This merging of functions simplifies the assembly process and reduces the number of assembly steps.
Solution Approach 2:
The patent extracts and removes the unnecessary fixing components (side plates, end plates, bolts, welding structures) from the traditional battery module assembly. By taking out these redundant elements and relying solely on the housing enclosure to secure the battery set, the assembly procedure becomes significantly simpler and less labor-intensive.
2Strength
If battery module structure with side plates and end plates is used, then the battery set is securely fixed, but the battery pack weight increases and internal space utilization decreases
Solution Approach 1:
The housing structure is designed to serve dual functions: it encloses the battery components and simultaneously provides the fixation mechanism for the battery set. By merging the enclosure and fixation functions into a single integrated structure, the need for additional heavy fixing components is eliminated, reducing overall weight while maintaining fixation strength.
3Strength
If battery module structure with side plates and end plates is used, then the battery set is securely fixed, but the battery pack internal space utilization decreases
Solution Approach 1:
The housing structure is designed to serve dual functions: it encloses the battery components and simultaneously provides the fixation mechanism for the battery set. By merging the enclosure and fixation functions into a single integrated structure, the need for additional heavy fixing components is eliminated, reducing overall weight while maintaining fixation strength.
4Strength
If traditional battery module assembly method is used, then the battery set is securely fixed, but the production cost increases due to complex assembly procedure
Solution Approach 1:
The housing structure is designed to serve dual functions: it encloses the battery components and simultaneously provides the fixation mechanism for the battery set. By merging the enclosure and fixation functions into a single integrated structure, the need for additional heavy fixing components is eliminated, reducing overall weight while maintaining fixation strength.
Data Source
AI summary
A battery pack includes a housing, and at least one housing structural beam and multiple electrode core strings electrically connected to one another located in the housing. The housing includes a housing body, including a top plate and a bottom plate arranged opposite to each other in a first direction. The structural beam is located between the top plate and the bottom plate, the at least one structural beam is connected to the top plate and the bottom plate, and divides the interior of the housing into multiple accommodating cavities, and at least one electrode core string is provided in at least one accommodating cavity. A mounting portion is provided on the housing, and the mounting portion is configured to be connected and fixed to an external load. The electrode core string includes multiple electrode core assemblies sequentially disposed in a second direction and connected in series.