Integrated Battery Pack Assembly With Bracket Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs have redundant components that perform the same function, leading to reduced productivity and increased weight, particularly in high-output power applications.
Innovation Solution
A simplified battery pack configuration that omits redundant components by using fixing brackets, support members, and a compression member to secure assembly and rigidity, while incorporating a bus bar assembly and cooling plate for electrical and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional battery packs use separate housings for battery modules and battery packs with multiple redundant components, then the structure provides sufficient protection and support, but the device complexity and weight increase, and productivity decreases
Solution Approach 1:
The patent merges the battery module housing and battery pack housing into a single integrated pack housing structure. The pack housing simultaneously accommodates multiple cell stacks and provides structural support, eliminating the need for separate module housings and reducing the number of fastening members required, thus simplifying the overall configuration while maintaining protective function
Solution Approach 2:
The pack housing is designed to perform multiple functions: it serves as the outer protective shell, the structural support framework, and the mounting structure for cell stacks. The fixing brackets also serve dual purposes by both securing cell stacks to the housing and providing compression force, reducing the need for separate compression components
2Reliability
If conventional battery packs include redundant components performing the same function, then the structure provides enhanced protection and support, but the weight of the battery pack increases
Solution Approach 1:
The patent combines multiple protective and support functions into fewer components. The single pack housing with integrated fixing brackets replaces what would traditionally require separate module housings, additional support brackets, and dedicated compression members, reducing total component count and weight while maintaining structural integrity
Solution Approach 2:
The patent extracts and eliminates redundant components from the conventional battery pack design. By removing separate module housings and unnecessary fastening members, the design achieves weight reduction while the remaining components (pack housing and fixing brackets) are optimized to provide sufficient protection and support through their integrated structure
3Productivity
If conventional battery packs use multiple separate components for assembly, then the structure provides adequate support and protection, but productivity and manufacturing efficiency decrease
Solution Approach 1:
The integrated pack housing design reduces the number of discrete components that need to be manufactured, inventoried, and assembled. The fixing brackets are designed to be directly attached to the pack housing, eliminating intermediate assembly steps and reducing manufacturing complexity, thereby improving productivity
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A battery pack, may include: a plurality of cell stacks including a plurality of battery cells; a pack housing accommodating the plurality of cell stacks; a fixing bracket disposed between the plurality of cell stacks and the pack housing and between the plurality of cell stacks; and a fastening member fastening the fixing bracket to the pack housing, wherein the fixing bracket may be disposed to contact the plurality of battery cells on an upper side of the plurality of cell stacks.