EV Battery Pack Cross-Member Layout for Cell Density and Rigidity
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Solution Overview
Problem
Existing battery packs for electric vehicles have a large area ratio of ancillary components such as mechanical components for rigidity, heat dissipation components, and insulation, which reduces the volume ratio of battery cells, thereby limiting the vehicle's cruising range.
Innovation Solution
The battery pack design incorporates a lower casing with first and second cross members that provide structural rigidity and cooling functions while maximizing the number of battery cells. The cross members are strategically placed between battery modules to minimize overlap and enhance packing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery modules are arranged adjacently in the battery pack, then the volume ratio of battery cells is maximized, but the structural rigidity of the battery pack deteriorates
Solution Approach 1:
The patent integrates the support function into the battery module housing itself. The housing includes a support protrusion that extends from the housing body to contact and support the battery module, eliminating the need for separate support components. This merging of support function into the existing housing structure maintains structural rigidity while maximizing battery cell density.
Solution Approach 2:
The battery module housing serves multiple functions: it provides structural enclosure for the battery cells, thermal management pathways, electrical isolation, and structural support through the integrated support protrusion. This multi-functionality reduces the need for additional dedicated support components, thereby maintaining rigidity while maximizing space utilization.
2Strength
If ancillary components such as mechanical components for rigidity and heat dissipation components are increased, then structural rigidity and cooling performance are improved, but the volume ratio of battery cells deteriorates
Solution Approach 1:
The patent combines multiple functions into integrated components. The housing structure integrates support functions through the support protrusion, and thermal management functions are incorporated into the housing design. This eliminates the need for separate mechanical rigidity components and dedicated support structures, thereby maximizing battery cell volume while maintaining structural integrity and cooling performance.
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides structural enclosure, thermal management pathways, electrical isolation, and structural support through the integrated support protrusion. This multi-functionality reduces the need for additional dedicated components, thereby maximizing the volume ratio of battery cells while maintaining rigidity and cooling performance.
3Quantity of substance
If battery modules are arranged adjacently in the width direction, then the packing efficiency is improved, but the gap space between modules creates structural weakness
Solution Approach 1:
The support function is merged into the battery module housing through the support protrusion. This protrusion extends from the housing body to contact and support adjacent battery modules, providing structural reinforcement at the interfaces where modules are arranged adjacently. This maintains structural strength while maximizing packing efficiency.
Solution Approach 2:
The support protrusion is pre-integrated into the housing structure before battery module assembly. This preliminary incorporation of support features ensures that structural reinforcement is already in place when battery modules are arranged adjacently, preventing structural weakness at the interfaces without requiring additional components or post-assembly modifications.
Data Source
AI summary
A battery pack for a vehicle includes a lower casing in which a terminal part of a battery module and a terminal part of another battery module adjust to each other in a width direction face each other and a plurality of battery modules are placed to be sequential in a longitudinal direction, a first cross member crossing the lower casing in the width direction and inserted between battery modules among the plurality of battery modules, which are placed adjacent to each other in the longitudinal direction, and a second cross member crossing the lower casing in the longitudinal direction, fastened to an upper end of the first cross member so as to be provided between battery modules among the plurality of battery modules, which are arranged adjacent to each other in the width direction, and electrically connected to the terminal part of the battery module.