Battery Pack Casing Structure for High-Pressure CTP Modules
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Solution Overview
Problem
Conventional battery pack assemblies using a cell-to-pack (CTP) structure face increased weight and material costs due to high surface pressure from large-area battery modules, necessitating additional bolting hardware, which complicates the design and increases costs.
Innovation Solution
A battery pack casing member is designed to directly support the surface pressure of large-area modules without a separate pack endplate, utilizing a fastening groove system to secure the endplate and casing member, thereby reducing material usage and weight while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate pack endplate is used to support the surface pressure of the battery module, then the structural integrity is improved, but the weight and material costs increase
Solution Approach 1:
The patent merges the function of the separate pack endplate into the battery pack casing member itself. The casing member is designed with an integrated structure that directly supports the surface pressure of the battery module, eliminating the need for a separate endplate component while maintaining the required structural integrity and pressure support capabilities.
Solution Approach 2:
The battery pack casing member is designed to perform multiple functions: it serves as both the protective enclosure and the surface pressure support structure. By making the casing member multi-functional, the patent eliminates the separate endplate while ensuring that the primary function of supporting surface pressure is effectively fulfilled.
2Strength
If a separate pack endplate with bolting hardware is used, then the surface pressure is supported, but the device complexity and material costs increase
Solution Approach 1:
The patent combines the endplate function and bolting hardware into the integrated casing member structure. The casing member incorporates built-in fastening features and mounting portions that eliminate the need for separate bolting hardware, thereby reducing device complexity while maintaining the ability to support surface pressure effectively.
Solution Approach 2:
The patent extracts and eliminates the separate endplate and bolting hardware components from the battery pack assembly. By removing these redundant components and integrating their functions into the casing member, the overall device complexity is reduced while the essential function of supporting surface pressure is preserved.
3Productivity
If the battery module area is increased to accommodate more cells, then the productivity is improved, but the surface pressure increases requiring more bolting hardware
Solution Approach 1:
The battery pack casing member is designed as a multi-functional component that simultaneously serves as the structural enclosure and the surface pressure support system. This integrated design allows the casing member to handle increased surface pressure from larger battery modules without requiring additional separate bolting hardware, thus supporting higher productivity while managing the increased pressure demands.
Data Source
AI summary
A vehicle battery pack assembly includes a battery module including a plurality of battery cells stacked and provided in a transverse direction, and an endplate provided at an outermost side of the battery module in a width direction of the battery module and formed with a mounting portion protruding outward therefrom; and a battery casing provided with a casing member extending along a longitudinal direction of the battery module, the casing member, of which a surface facing toward the battery module is in surface-contact with the endplate to support a surface pressure of the battery module, wherein the casing member includes a fastening groove formed at a point corresponding to the mounting portion, wherein the mounting portion is inserted in the fastening groove and fastened to the casing member.