Battery Pack Tray-Vapor Chamber Joint Against Edge Beam Deformation
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Solution Overview
Problem
The edge beam of the tray in battery packs is prone to deformation during collisions, leading to potential battery squashing and safety hazards such as short circuits.
Innovation Solution
A battery pack design incorporating a vapor chamber with first edge portions coupled to first edge beams, featuring a clamping slot for enhanced structural support, and additional features like cooling tubes and heaters to enhance stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the edge beam is designed to be light in weight and cost reductive, then the manufacturing cost is reduced and weight is decreased, but the strength and resistance to deformation is insufficient
Solution Approach 1:
The vapor chamber is integrated with the edge beam to form a combined structure. The edge beam and vapor chamber work together as a unified load-bearing component, where the vapor chamber provides additional structural support and force distribution capability, resolving the contradiction between lightweight design and strength requirements
Solution Approach 2:
The edge beam structure combines different materials and components (the beam itself and the vapor chamber) to create a composite structure that achieves both lightweight properties and high strength. The vapor chamber acts as a reinforcing element that enhances the overall mechanical performance without significantly increasing weight
2Weight of moving object
If the edge beam is designed to be light in weight, then the weight is decreased, but the ability to resist squashing and deformation during collision is reduced
Solution Approach 1:
The vapor chamber is merged with the edge beam structure to create a combined system that provides both lightweight properties and high collision resistance. The integration allows the vapor chamber to act as a protective and reinforcing element that enhances deformation resistance while maintaining low weight
Solution Approach 2:
The vapor chamber structure provides beforehand cushioning and force distribution capability to the edge beam. During collision, the vapor chamber absorbs and distributes impact forces before they can cause deformation to the battery module, ensuring reliability while keeping the edge beam lightweight
3Strength
If the vapor chamber is integrated with the edge beam, then the structural strength is increased, but the device complexity is increased
Solution Approach 1:
The vapor chamber and edge beam are merged into a single integrated structure, which strengthens the tray while avoiding the complexity of separate mounting systems. The integration eliminates the need for additional fasteners, brackets, or assembly steps that would increase device complexity
Solution Approach 2:
The vapor chamber serves multiple functions simultaneously: it acts as a structural reinforcement element, a thermal management component, and a force distribution mechanism. This multi-functionality allows the structure to achieve high strength without adding dedicated components for each function, thereby controlling overall complexity
Data Source
AI summary
A battery pack includes a tray and a vapor chamber. The tray includes two first edge beams, and the two first edge beams are respectively disposed on two opposite sides of a receiving space having a top opening. The vapor chamber is disposed at the top opening of the tray and comprises two opposite first edge portions, and the two first edge portions are respectively mounted on the two first edge beams. One of a first edge beam and a corresponding first edge portion mounted thereon comprises an inner surface that faces the receiving space and includes a clamping slot, and the other one of the first edge beam and the corresponding first edge portion is inserted into the clamping slot.