Battery Pack Cross Beam Layout for Cell Laminate Positioning
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Solution Overview
Problem
Conventional battery packs face issues such as increased manufacturing costs, reduced cooling performance, poor space utilization, and lower energy density due to interference from welding beads and the need for additional components. Additionally, regulating the initial installation position of cell laminates in simplified cell-to-pack structures without module housings is challenging.
Innovation Solution
The proposed pack case design features a double-layered cross beam structure with a lower cross beam welded to the base plate and an upper cross beam coupled to the lower cross beam. This configuration allows for easy welding and improved accessibility for the loading jig, while the fastening grooves in both cross beams regulate the installation position of cell laminates, preventing interference from welding beads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single cross beam is welded directly to the base plate, then welding operation is simple, but welding beads interfere with cell laminate installation and reduce space utilization
Solution Approach 1:
The cross beam is divided into two separate layers: a lower cross beam welded to the base plate and an upper cross beam coupled to the lower cross beam. This segmentation allows the welding operation to be performed on the lower cross beam without generating beads that would interfere with cell laminate installation, while the upper cross beam provides the necessary structural support and positioning features.
Solution Approach 2:
The cross beam structure transitions from a single-plane configuration to a multi-layer three-dimensional structure. The lower cross beam resides in a lower plane for welding, while the upper cross beam is positioned in an upper plane, creating vertical separation that eliminates bead interference while maintaining structural integrity.
2Device complexity
If module housing is removed for cell-to-pack structure, then structure is simplified, but regulating cell laminate installation position becomes difficult
Solution Approach 1:
The upper cross beam acts as an intermediary structure that provides positioning features (such as positioning grooves or reference surfaces) for the cell laminates. This mediator enables precise position regulation without requiring the complex module housing structure, maintaining simplicity while achieving manufacturing precision.
3Reliability
If loading jig grips cell laminates deeply for stable transport, then transport stability is improved, but interference with cross beam makes installation difficult
Solution Approach 1:
The loading jig operates in the vertical dimension by gripping cell laminates from above, while the upper cross beam is positioned at a different vertical level. This dimensional separation allows the loading jig to maintain deep gripping for stable transport without interfering with the cross beam structure during installation.
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 solution simplifies the battery pack structure, enhances space utilization and energy density by eliminating welding bead interference, and ensures precise positioning of cell laminates even in simplified cell-to-pack configurations, thereby improving productivity and safety.
Implementation Method 1
a lower cross beam coupled to the base plate
Data Source
AI summary
A pack case includes a base plate, a side plate, a lower cross beam, and an upper cross beam. The side plate is coupled along a periphery of the base plate to form a receiving space therein, the lower cross beam is coupled to the base plate to transversely divide the receiving space inside the base plate, and the upper cross beam is coupled to the lower cross beam. The lower cross beam and the upper cross beam are each provided with fastening grooves to regulate the installation position of a cell laminate.