Battery Pack Tray-End Plate Structure for Module Protection Density
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Solution Overview
Problem
Existing battery packs face challenges in achieving structural stability and high energy density due to space inefficiencies and the need for additional components like crash beams and wire harnesses.
Innovation Solution
The battery pack design includes a pack case with a tray and top cover, where battery modules are mounted with end plates providing mechanical support, eliminating the need for a crash beam and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crash beam is added to protect battery modules, then reliability is improved, but device complexity increases and space is reduced
Solution Approach 1:
The end plate is merged with the tray to form an integrated structure. The tray serves as both the mounting surface for battery modules and the protective structural element, eliminating the need for a separate crash beam. This integration reduces component count and structural complexity while maintaining protection functionality.
Solution Approach 2:
The tray is designed to serve multiple functions: it mounts the battery modules, provides structural support, and acts as the protective beam equivalent. By making the tray multi-functional, the patent eliminates the need for dedicated protective components like crash beams, thereby reducing device complexity.
2Reliability
If a crash beam is added to protect battery modules, then reliability is improved, but the floor area ratio is reduced
Solution Approach 1:
By merging the end plate with the tray, the protective function is integrated into the existing structural component that occupies the floor area. This eliminates the need for additional protective components that would further reduce the available floor area, thus maximizing the floor area ratio while maintaining protection.
3Ease of operation
If wire harnesses are installed between battery modules, then electrical connection is achieved, but space is consumed and device complexity increases
Solution Approach 1:
The wire harness is integrated with the tray structure, combining the electrical connection function with the mechanical support structure. This integration reduces the need for separate wire routing channels and mounting structures, thereby reducing device complexity while maintaining electrical connectivity.
4Reliability
If battery modules are mounted with spacing for protection, then reliability is improved, but the floor area ratio is reduced
Solution Approach 1:
The protective function is merged into the tray-end plate structure itself, which provides structural support and protection without requiring additional spacing between battery modules. The integrated structure distributes mechanical loads and provides protection through its design rather than through spacing, thereby maximizing the floor area ratio.
Data Source
AI summary
Provided are a battery pack with structural stability of battery modules and improved energy density, and a vehicle comprising the same. The battery pack according to the present disclosure includes at least one battery module and a pack case for receiving the battery module, the battery module including a battery cell stack including at least one battery cell, and a pair of end plates provided in close contact with front and rear sides of the battery cell stack on two sides of a lengthwise direction of the battery cell, and the pack case including a tray in which the battery module is mounted on an upper surface, and a top cover of which an outer periphery is coupled in contact with an outer periphery of the tray on the upper surface of the tray when the battery module is received inside, and wherein the end plates provide a mechanical support to protect the battery cell.