Battery Pack Frame Integrating Holder and Case Wall
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Solution Overview
Problem
Conventional battery packs have low energy density due to the space taken up by cases, holders, and other components, leading to a need for an improved design that enhances energy storage efficiency.
Innovation Solution
The battery pack incorporates a frame that immobilizes batteries within the case, with the frame's perimeter serving as the outermost wall, reducing weight and space duplication, and includes a modular design with sub-packs in series and parallel configurations, along with a removably coupled electrical connector for adaptable voltage output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery packs use separate cases, holders, and components to secure batteries, then the batteries are held in position, but the energy density decreases due to the space and weight occupied by these components
Solution Approach 1:
The frame is designed to simultaneously serve as both the battery holder and the outer case structure. The frame includes compartments that secure batteries while its outer perimeter forms the protective case wall, eliminating the need for separate holder and case components. This merging of functions directly increases energy density by removing redundant structural elements.
Solution Approach 2:
The frame performs multiple functions: it holds batteries in position through internal compartments, provides structural support, and forms the outer protective case wall. This multi-functional design replaces what would traditionally require separate components (holder, case, mounting structure), thereby increasing the proportion of volume available for energy-storing batteries.
2Quantity of substance
If the frame serves as both battery holder and outer case wall, then the energy density increases, but the manufacturing complexity may increase
Solution Approach 1:
The frame is designed with modular compartments that can be formed using standard injection molding techniques. The segmentation into battery-receiving compartments and outer wall portions allows for efficient mold design and manufacturing, reducing the complexity despite the multi-functional nature of the component.
Solution Approach 2:
The frame height parameter is specifically designed to be within 80%-120% of the battery height, optimizing the balance between protective coverage and material usage. This parameter optimization ensures the frame is neither excessively large (wasting material) nor too small (inadequate protection), streamlining the manufacturing process.
3Adaptability or versatility
If removable electrical connectors are used for different voltage configurations, then the adaptability increases, but the device complexity increases
Solution Approach 1:
The electrical connector system is designed to be dynamically reconfigurable through removable connectors that can be attached or detached to change voltage configurations. This dynamic adaptability allows the battery pack to switch between series and parallel connections without redesigning the entire electrical system, managing complexity through modularity.
Solution Approach 2:
The electrical connector system is segmented into removable components that can be independently configured. This segmentation allows different voltage configurations to be achieved by simply changing the connector arrangement rather than redesigning the entire electrical system, making the complexity manageable through standardized modular components.
Data Source
AI summary
The battery pack includes a case that contains batteries and includes terminals through which power from the batteries can be accessed. The battery pack also includes a frame that defines battery receiving compartments that are each configured to receive one of the batteries with the frame immobilizing the position of each battery relative to the other batteries. The frame has a perimeter and at a portion of the frame perimeter serves as an outermost wall of the case.