Battery Pack Support Frame for Cell Expansion Absorption
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Solution Overview
Problem
Secondary batteries expand in the width direction due to repeated charging and discharging, causing deformation of the battery package and degrading electrical performance, which existing battery packs fail to adequately address.
Innovation Solution
A battery pack design featuring a support frame with inclined surfaces and a coupling mechanism that absorbs expansion pressure, ensuring ease of assembly and maintaining structural integrity while accommodating high energy density batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If secondary batteries are repeatedly charged and discharged to achieve high energy density, then power output is improved, but battery expansion in width direction occurs causing package deformation and electrical performance degradation
Solution Approach 1:
The support frame with inclined surfaces is designed in advance to accommodate and absorb the expansion pressure that will occur during battery operation. The inclined surfaces create a progressive contact mechanism that cushions the battery from the beginning of expansion, preventing deformation before it occurs rather than reacting after damage has happened.
Solution Approach 2:
The support frame structure applies a preliminary counteracting force through its inclined surfaces that oppose the expansion direction of the battery. This anti-action is built into the geometry of the support frame, creating a pre-positioned mechanical constraint that counteracts the harmful expansion force before it can cause deformation or performance degradation.
2Strength
If rigid support structures are used to prevent battery expansion, then structural integrity is improved, but assembly complexity and difficulty increase
Solution Approach 1:
The support frame transitions from a static rigid structure to a dynamic adaptive structure through its inclined surfaces. As the battery expands, the inclined surfaces allow the support frame to progressively engage and adjust to the expansion pressure, creating a dynamic response rather than a fixed rigid constraint. This dynamic behavior maintains structural integrity while simplifying assembly.
Solution Approach 2:
The inclined surfaces of the support frame introduce asymmetric geometry that provides both structural strength and assembly ease. The asymmetric angle allows the frame to be easily inserted in one direction while providing progressive resistance to expansion in the opposite direction, combining manufacturing simplicity with structural integrity.
3Reliability
If expansion absorption structures are added to accommodate battery swelling, then battery reliability is improved, but device complexity increases
Solution Approach 1:
The support frame with inclined surfaces serves multiple functions simultaneously: it provides structural support for the battery pack, absorbs expansion pressure through its geometric design, and guides proper assembly through its asymmetric shape. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity while maintaining reliability.
Solution Approach 2:
The expansion absorption function is merged into the existing support frame structure rather than being implemented as a separate component. The inclined surfaces of the same support frame that provides mechanical support also serve as the expansion absorption mechanism, combining structural support and pressure absorption into a single integrated element.
Data Source
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AI summary
A battery pack (1, 1') includes one or more battery modules (10, 10') including a cell stack (100, 100') including a plurality of battery cells (1000, 1000') stacked in a first direction, and a side cover (400) opposing the cell stack (100, 100') in the first direction; and a support frame (22) opposing the one or more battery modules (10, 10') in the first direction, wherein the side cover (400) includes a first inclined surface (421a) opposing the support frame (22) and inclined with respect to the first direction.