Battery Pack Frame Design for Capacity and Safety
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Solution Overview
Problem
Conventional battery packs face challenges in increasing capacity while ensuring safety, as enlarging batteries poses safety risks, and combining multiple batteries complicates the structure and increases production costs.
Innovation Solution
A battery pack design that incorporates multiple secondary batteries with a single PCM assembly, secured by a sub-frame and main frames, which simplifies the structure, reduces parts, and enhances stability, allowing for easy modification to accommodate different battery shapes and sizes, thereby improving manufacturing efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple secondary batteries are included in one battery pack to increase capacity, then the battery capacity increases, but the structure becomes complicated and the number of components increases
Solution Approach 1:
Multiple secondary batteries are accommodated within a single battery pack housing with a unified frame structure, merging multiple battery units into one integrated assembly. This reduces the number of separate components compared to having individual battery housings for each cell, while still providing high capacity through the combination of multiple batteries.
2Quantity of substance
If the size of secondary batteries is increased to enhance capacity, then the battery capacity increases, but safety problems arise
Solution Approach 1:
The battery system is segmented into multiple smaller secondary batteries rather than using one large battery. This segmentation approach maintains high overall capacity while improving safety, as smaller individual batteries pose reduced safety risks compared to a single large battery of equivalent total capacity.
3Quantity of substance
If multiple secondary batteries are accommodated in a battery pack, then the battery capacity increases, but the number of components increases leading to higher production costs
Solution Approach 1:
The battery pack housing and frame structure serve multiple functions simultaneously: they provide mechanical support for multiple batteries, offer protective enclosure, enable thermal management pathways, and facilitate electrical connections. This multi-functionality reduces the total number of separate components needed, simplifying manufacturing and reducing production costs despite accommodating multiple batteries.
Data Source
AI summary
A battery pack comprising: a first battery cell; a second battery cell; and a frame accommodating the first and second battery cells; wherein the battery cells each comprise a respective electrode terminal and the frame comprises a hole, the location of the hole corresponding to the location of at least one of the electrode terminals.