Battery Pack Box Structure to Prevent Bottom Deflection
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Solution Overview
Problem
The existing methods for fixing battery packs at the bottom of vehicles face structural strength challenges, leading to safety issues and design complexities due to insufficient weight distribution, resulting in increased weight, cost, and reduced energy density.
Innovation Solution
A battery pack design featuring a first and second battery module housed in a box body with a first and second connecting portion, where the connecting portions are fixed and connected to enhance structural strength, including protrusions and recesses for tight fit and a connecting beam for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fixing points are arranged only at the peripheries of the box body, then the device complexity is reduced, but the strength of the battery pack is insufficient
Solution Approach 1:
The battery pack structure is segmented into upper and lower box bodies with multiple connecting portions distributed throughout the structure. This segmentation allows strength to be distributed across multiple locations rather than concentrated at peripheries only, resolving the contradiction between strength and complexity.
Solution Approach 2:
The fixing points are extended from a two-dimensional peripheral arrangement to a three-dimensional distribution throughout the box body structure, including internal connecting portions. This dimensional expansion provides additional strength without proportionally increasing complexity.
2Strength
If the box body is made strong enough to distribute weight to each fixing point, then the strength is improved, but the weight increases
Solution Approach 1:
The box body is divided into upper and lower sections with multiple connecting portions, distributing the weight-bearing function across several smaller structural elements rather than requiring one heavily reinforced single structure, thus reducing overall weight while maintaining strength.
Solution Approach 2:
The connecting portions serve dual functions: they provide structural strength for weight distribution and act as fixing points for mounting. This merging of functions eliminates the need for separate reinforcement structures, reducing weight.
3Strength
If more welding is used to achieve the desired strength, then the strength is improved, but the manufacturing cost increases
Solution Approach 1:
The segmented structure with multiple connecting portions allows for modular assembly with reduced welding requirements compared to a monolithic strong structure. Each connection point requires less welding, and the modular nature simplifies manufacturing processes.
Solution Approach 2:
The design changes the structural parameters by distributing connections throughout the box body rather than concentrating them, which reduces the welding volume required at each location and simplifies the overall manufacturing process while maintaining strength.
4Strength
If the box body design is optimized for strength, then the strength is improved, but the energy density decreases
Solution Approach 1:
The segmented box body design uses thin-walled sections connected by multiple lightweight connecting portions, achieving required strength with minimal material usage. This preserves more volume for battery modules, maintaining high energy density.
Solution Approach 2:
The connecting portions are integrated into the battery pack structure itself rather than being separate reinforcement elements, eliminating dead weight and maximizing the volume available for energy-storing components.
Data Source
AI summary
The present application is provided with a battery pack, including a first battery module, a second battery module and a box body, where the first battery module and the second battery module are housed in the box body; the box body including a lower box body configured to support the first battery module and the second battery module, and an upper box body fitting with the lower box body. The lower box body includes a first connecting portion, and the first connecting portion is located between the first battery module and the second battery module. The upper box body includes a second connecting portion, where the first connecting portion and the second connecting portion are fixed and connected. In the battery pack of the present application, the problem of downward deflection of the lower box body is avoided and the strength of the battery pack is improved.