Battery Pack Case Frame with Integrated Side and End Plates
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Solution Overview
Problem
Existing battery packs face challenges in efficiently assembling multiple battery cells with sufficient coupling strength, which is crucial for high-output and high-capacity applications such as electric vehicles and hybrid electric vehicles.
Innovation Solution
A battery pack design featuring a case frame with side plates and an end plate formed in one piece, utilizing a hook coupling structure with catch jaws and coupling tabs for secure assembly without joints, and a position alignment structure for precise alignment, allowing for easy assembly and enhanced mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional coupling structures with joints are used to assemble battery cells, then assembly is easier, but coupling strength and mechanical strength are insufficient
Solution Approach 1:
The side plates and end plate are merged into a single integrated case frame component formed in one piece, eliminating joints between these structural elements. This integration maintains coupling strength while simplifying the overall assembly structure by reducing the number of separate parts that need to be joined together.
Solution Approach 2:
The case frame is segmented into functional components: side plates for lateral support and end plates for terminal closure, while the finishing plate is separated as a distinct assembly component. This segmentation allows each part to be optimized for its specific function while maintaining ease of assembly through modular construction.
2Ease of manufacture
If multiple separate components are used for the case frame, then manufacturing is easier, but assembly time and coupling reliability decrease
Solution Approach 1:
The side plates and end plate are combined into a single molded case frame component, reducing the number of assembly steps required. This integration maintains manufacturing ease through single-piece molding while significantly reducing assembly time by eliminating the need to join multiple frame components together.
3Reliability
If a secure coupling structure is implemented, then battery cells are firmly held, but assembly difficulty increases
Solution Approach 1:
The coupling mechanism is segmented into complementary features: protrusions on the battery cell case and corresponding recesses on the finishing plate. This segmentation creates simple, foolproof assembly through direct snap-fit engagement while maintaining reliable mechanical coupling that firmly holds the battery cells in place.
4Adaptability or versatility
If joints are used to connect side plates and end plate, then manufacturing flexibility is improved, but structural integrity and strength are reduced
Solution Approach 1:
The side plates and end plate are merged into a single integrated case frame component formed by molding. This eliminates joints that would compromise structural integrity while maintaining manufacturing flexibility through the molding process, which can accommodate various design configurations and battery cell arrangements.
Data Source
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AI summary
A battery pack is disclosed. The battery pack includes a plurality of battery cells (10) arranged in a first direction (Z1), a case frame (160) having an opened end to receive the battery cells, and a finishing plate (120) configured to be coupled to the opened end of the case frame. The case frame includes a pair of side plates (140) extending in the first direction and an end plate (150) disposed between the side plates to form a closed end opposite to the opened end. The side plates and the end plate are formed in one piece. The battery pack has an improved coupling structure for easily assembling multiple battery cells as a module and providing sufficient coupling strength between the finishing and side plates.