Battery Pack Cross-Beam Structure for Higher Energy Density
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Solution Overview
Problem
Existing battery packs face challenges in achieving improved energy density, which is crucial for enhancing the driving efficiency and range of mobility applications.
Innovation Solution
The battery pack design includes a housing with a cooling plate and a center plate, featuring first and second battery cell assemblies with cross-beams of different shapes, and a reinforcing part coupled to the center beam, which enhances mechanical strength and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional battery pack structure is used, then manufacturing is simpler, but energy density is insufficient
Solution Approach 1:
The battery pack is divided into modular battery cell assemblies, each with its own cross-beam structure. This segmentation allows for optimized energy density in each module while maintaining overall structural integrity through standardized interfaces and reinforcing parts.
Solution Approach 2:
The first and second cross-beams are designed with different shapes that are complementary to each other. This asymmetric design optimizes the structural distribution to achieve higher energy density while maintaining mechanical strength, rather than using identical symmetric structures.
2Strength
If cross-beams are not reinforced, then structure is simpler, but mechanical strength is insufficient
Solution Approach 1:
The reinforcing part combines multiple functions: it reinforces the lower center beam, provides coupling surfaces for both the first and second cross-beams, and integrates with the cooling plate. This merging of functions increases mechanical strength without proportionally increasing structural complexity.
Solution Approach 2:
The reinforcing part acts as an intermediary element that mediates between the lower center beam and the cross-beams. It provides a standardized interface that simplifies assembly while distributing mechanical loads effectively across the battery pack structure.
3Strength
If more reinforcing parts are added, then mechanical strength improves, but manufacturing complexity increases
Solution Approach 1:
The reinforcing part is designed as a universal component that serves multiple purposes: reinforcing the center beam, coupling both types of cross-beams, and integrating with the cooling system. This multi-functionality reduces the total number of different part types needed, simplifying manufacturing and assembly processes.
Data Source
AI summary
A battery pack may include a housing including a cooling plate and a center plate, the cooling plate including cooling channels and the center plate including a lower center beam, a first battery cell assembly and a second battery cell assembly that are disposed on the cooling plate, and a reinforcing part coupled to the lower center beam. In addition, each of the first and second battery cell assemblies may include a cell stack, a first cross-beam, and a second cross-beam, the first cross-beam and the second cross-beam being spaced apart from each other with the cell stack interposed therebetween. Further, a shape of the first cross-beam and a shape of the second cross-beam can be different to each other, and the first cross-beam of the second battery cell assembly can be coupled to the reinforcing part.