Battery Pack Cross-Beam Structure for Strength and Energy Density
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Solution Overview
Problem
Existing battery packs face challenges in achieving improved energy density and mechanical strength, particularly in applications requiring high energy efficiency and safety.
Innovation Solution
A battery pack design incorporating a housing with a cooling plate and center plate, featuring cross-beams with complementary shapes, reinforcing parts, and buried fixing devices to enhance structural integrity and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery pack structures are used, then manufacturing is simpler, but mechanical strength and energy density are insufficient
Solution Approach 1:
The battery pack structure is segmented into modular components including first and second battery cell assemblies, each with dedicated cross-beams (first and second cross-beams) for localized reinforcement. The housing is divided into functional sections with a cooling plate, center plate, and support plate, allowing independent optimization of each segment for both strength and manufacturing efficiency
Solution Approach 2:
The first cross-beam and second cross-beam are designed with different shapes that are complementary to each other. The first cross-beam has a first shape while the second cross-beam has a second shape that complements the first, creating an asymmetric but interlocking structural system that maximizes mechanical strength while maintaining manufacturability
2Quantity of substance
If battery cell assemblies are densely packed, then energy density improves, but mechanical stability decreases
Solution Approach 1:
The cross-beams serve multiple functions: they provide mechanical reinforcement for structural stability, create mounting positions for battery cell assemblies to maximize packing density, and form interlocking patterns that enhance overall pack integrity. The reinforcing parts coupled to the lower center beam provide additional multi-functional support for both stability and density
Solution Approach 2:
The cross-beams are designed with predetermined shapes and positions that pre-establish the optimal arrangement for battery cell assemblies. The complementary shapes of the cross-beams are designed in advance to interlock and prevent movement, ensuring mechanical stability is built into the structure before battery cells are installed, allowing maximum energy density to be achieved
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
The design improves mechanical strength and energy density by utilizing cross-beams with complementary shapes and reinforcing parts, enhancing safety and efficiency in battery packs.
Implementation Method 1
a housing including a cooling plate and a center plate, the cooling plate including cooling channels
Data Source
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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.