Battery Pack Tray Assembly for Higher Cell Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The configuration of battery modules in existing battery packs reduces the actual number of battery cells that can be mounted, affecting vehicle mileage and requiring complex assembly processes.
Innovation Solution
A battery pack design where battery cells are directly mounted on a pack tray with sensing blocks and a pressure plate, using horizontally deformed cell bus-bars and spacers for support, and incorporating flexible printed circuit boards for electrical connections, along with insulation and cooling channels for stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery modules are used with supporting parts to secure rigidity, then structural stability is improved, but the actual number of mounted battery cells decreases
Solution Approach 1:
The battery pack is divided into multiple battery packs, with each battery pack containing a specific number of battery cells (e.g., 5 cells per pack). This segmentation allows for efficient space utilization and eliminates the need for additional supporting parts between individual cells, thereby increasing the total number of mounted cells while maintaining structural stability through the modular arrangement.
Solution Approach 2:
Multiple battery cells are directly mounted and coupled together in a stacked arrangement within each battery pack, merging their structural functions. The cells support each other through direct coupling rather than requiring separate supporting parts, which increases the number of mountable cells while maintaining rigidity through the combined structure.
2Quantity of substance
If battery cells are directly mounted on pack tray, then the number of mounted battery cells increases, but assembly complexity increases
Solution Approach 1:
The battery pack is segmented into modular units with a standardized number of cells (e.g., 5 cells per pack). This segmentation creates a repeatable assembly pattern that simplifies the overall assembly process, as each module can be assembled and installed as a unit, reducing the complexity despite the increased number of cells.
Solution Approach 2:
The battery cells within each pack are pre-arranged and pre-coupled in a standardized configuration before installation. The bus bars and supporting structures are prepared in advance with predetermined positions and orientations, which simplifies the final assembly process and reduces on-site complexity.
3Reliability
If cell bus-bars are deformed horizontally to avoid interference, then electrical connection is improved, but manufacturing complexity increases
Solution Approach 1:
The cell bus-bars are pre-deformed into their final horizontal configuration during the manufacturing process, before installation. This preliminary deformation ensures that the bus bars are ready for immediate electrical connection without requiring additional on-site bending or deformation, which simplifies installation while maintaining the electrical connection reliability achieved through the horizontal orientation.
Data Source
AI summary
A battery pack for a vehicle includes a pack tray with an open upper surface, a plurality of battery cells stacked in a vertical direction on the pack tray, a plurality of sensing blocks, each including a cell bus-bar connected to an electrode of each of the battery cells, and provided on the pack tray, and a pressure plate mounted to press upper surfaces of the stacked battery cells in a downward direction, wherein the pack tray includes a plurality of support members fixing the plurality of sensing blocks, and wherein the pressure plate is fixed to the support members with the plurality of sensing blocks and is located above the plurality of sensing blocks.