Vehicle Battery Pack Cross Member Layout for Cell Density
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Solution Overview
Problem
Existing battery packs for electric vehicles have a high volume percentage of ancillary components such as mechanical components for rigidity, heat dissipation components, and insulation components, which reduces the space available for battery cells, thereby limiting the vehicle's range.
Innovation Solution
The battery pack design incorporates a crossing member that extends across the lower casing between adjacent battery modules, providing structural rigidity while minimizing ancillary components. This design maximizes the volume percentage of battery cells and maintains cooling and insulating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate covers and housings are provided for each battery cell and module, then mechanical rigidity and protection are ensured, but the volume percentage of ancillary components increases, reducing the space for battery cells
Solution Approach 1:
The patent merges the functions of the lower casing, crossing members, and end plates into an integrated structural system that provides mechanical rigidity for the entire battery pack while minimizing the number of separate components. The lower casing integrates support functions, and the crossing members combine structural reinforcement with battery module spacing functions.
Solution Approach 2:
The lower casing serves multiple functions: it provides mechanical support, acts as a mounting structure for battery modules, and integrates cooling channel pathways. The end plates simultaneously provide structural closure, mechanical reinforcement, and mounting surfaces for electrical connections.
2Temperature
If more ancillary components are used for cooling and insulation, then thermal management and protection performance are improved, but the volume percentage of battery cells decreases
Solution Approach 1:
The cooling channels are integrated directly into the lower casing structure, eliminating the need for separate cooling plates or housings. The crossing members also incorporate cooling channel pathways, combining structural support with thermal management functions in a single component.
3Ease of manufacture
If traditional separate component design is used, then manufacturing and assembly are simplified, but the overall structural rigidity and airtightness under vibration and shock are insufficient
Solution Approach 1:
The patent creates an integrated structural system where the lower casing, crossing members, and end plates work together as a unified load-bearing assembly. This integrated design provides continuous structural support and airtight sealing throughout the battery pack, improving reliability under vibration and shock while maintaining manufacturing feasibility.
Data Source
AI summary
A battery pack for a vehicle includes a lower casing in which a plurality of battery modules is seated, and a crossing member disposed to cross the lower casing along a widthwise direction between the battery modules seated to be adjacent in a lengthwise direction, being in close contact with end plates of the battery modules, lateral sides of which face each other, and being fastened to the lower casing together with a pair of end plates disposed at both lateral sides.