Battery Pack Cross-Beam Structure for Width-Direction Strength
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Solution Overview
Problem
Existing battery packs for electric vehicles have insufficient structural strength in directions perpendicular to the internal beams, leading to reduced safety and stability, especially during collisions or extrusions due to the absence of beams in these directions.
Innovation Solution
A battery pack design incorporating a cell dummy with a support beam perpendicular to the mounting beam within the housing, enhancing structural strength in the width direction and providing additional support through integration or adhesive filling, while maintaining strength in the length direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If only longitudinal mounting beams are arranged in the housing, then the battery pack structure is simple and easy to manufacture, but the strength in the width direction is insufficient
Solution Approach 1:
The patent introduces transverse support beams perpendicular to the longitudinal mounting beams, transforming the single-direction beam arrangement into a two-dimensional grid structure. This dimensional expansion provides structural reinforcement in the previously weak width direction without requiring complete redesign of the entire beam system.
Solution Approach 2:
The support beam is divided into multiple segments (first support beam and second support beam) that can be independently arranged and connected to the mounting beams. This segmentation allows flexible integration into the existing structure, providing width-direction strength while maintaining manufacturing simplicity through modular assembly.
2Reliability
If transverse support beams are added to the housing, then the strength for resisting extrusion and collision is improved, but the device complexity increases
Solution Approach 1:
The support beams are integrated with the existing mounting beams through connection structures, merging the longitudinal and transverse beam functions into a unified structural system. This integration ensures that the enhanced safety performance is achieved while minimizing the increase in device complexity through coordinated design of beam intersections.
Solution Approach 2:
The support beams are pre-positioned and connected to the mounting beams before final assembly of battery cells. This preliminary structural preparation ensures that the reinforcement framework is already in place to resist extrusion and collision forces, improving safety without requiring complex post-assembly modifications.
3Strength
If the support beam is integrally formed with the mounting beam, then the structural strength is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
Connection structures serve as intermediaries between the support beams and mounting beams, providing standardized interfaces that facilitate precise alignment and strong bonding. These intermediaries absorb manufacturing tolerances and enable reliable integration without requiring extremely high precision across the entire beam system.
Solution Approach 2:
The patent employs composite construction where support beams and mounting beams (potentially made of different materials or with different properties) are joined through connection structures. This composite approach allows optimization of each beam component for its specific function while using the connection interface to achieve overall structural strength without demanding excessive precision from individual components.
Data Source
AI summary
A battery pack and an electric apparatus are disclosed. The battery pack includes a cell dummy and multiple battery cells, a housing, a mounting beam, and a support beam. The housing is provided with an accommodating cavity, and the cell dummy and the multiple battery cells are all disposed in the accommodating cavity. The mounting beam is disposed in a length direction of the accommodating cavity and defines, together with the accommodating cavity, a mounting space for accommodating the cell dummy and the multiple battery cells. The support beam is disposed in a width direction of the accommodating cavity and is mounted in a manner of fitting with the cell dummy. The cell dummy being provided with the support beam perpendicular to the mounting beam can enhance structural strength of the battery pack in the width direction of the accommodating cavity.