Battery Pack Coupling Structure for Vibration-Stable Module Fastening
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Solution Overview
Problem
Existing battery packs face challenges in simplifying the fastening process between battery modules and the pack housing while ensuring structural stability, particularly under conditions of vibration and shock.
Innovation Solution
A battery pack design featuring a module stack supported by a lower and upper housing, with displacement plates elastically pressing the stack, and fastening bolts penetrating through the pack housing and coupled with weld nuts, along with an airtight plate assembly to prevent moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex fastening system is used to ensure structural stability under vibration, then reliability improves, but device complexity increases
Solution Approach 1:
The displacement plate integrates multiple functions: it serves as both a fastening element (replacing separate bolts and clamps) and a pressing mechanism (applying elastic force to secure battery modules). This merging of functions reduces the number of components while maintaining structural stability under vibration.
Solution Approach 2:
The displacement plate utilizes elastic deformation as its working principle, changing from a rigid fastening system to one incorporating elastic elements. This parameter change allows the structure to absorb vibration energy while maintaining secure fastening, improving reliability without increasing complexity.
2Reliability
If multiple fastening components are used to secure battery modules, then connection reliability improves, but manufacturing cost increases
Solution Approach 1:
The displacement plate combines the functions of multiple fastening components (bolts, clamps, and pressing mechanisms) into a single integrated element. This reduces the total number of parts that need to be manufactured, assembled, and inventoried, thereby lowering manufacturing costs while maintaining connection reliability.
Solution Approach 2:
The displacement plate is designed as a multi-functional component that simultaneously provides fastening, pressing, and positioning functions for battery modules. This universality reduces the need for specialized components, simplifying manufacturing processes and reducing overall production costs.
3Stability of the object's composition
If rigid fastening structures are used to prevent movement, then structural stability improves, but shock resistance deteriorates
Solution Approach 1:
The displacement plate incorporates elastic deformation capability, changing the fastening system from rigid to flexible. This allows the structure to absorb shock energy through elastic deformation while maintaining stable positioning of battery modules, simultaneously improving both structural stability and shock resistance.
Solution Approach 2:
The elastic displacement plate acts as a pre-designed cushioning element that absorbs shock energy before it can damage the battery modules or housing. This beforehand cushioning mechanism protects the structural integrity during vibration and shock events.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances fastening simplicity and structural stability, while providing shock resistance and preventing performance degradation due to vibration and moisture ingress.
Implementation Method 1
a plurality of displacement plates respectively coupled to inner sides of the lower housing and the upper housing to elastically press the module stack
Data Source
AI summary
Disclosed is a battery pack, which includes a module stack in which a plurality of battery modules are stacked; a pack housing having a lower housing configured to support the module stack at a lower side thereof and an upper housing coupled to the lower housing from an upper side of the module stack; and a plurality of displacement plates respectively coupled to inner sides of the lower housing and the upper housing to elastically press the module stack.