Battery Pack Frame Positioning for Impact Protection
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Solution Overview
Problem
Battery packs face challenges in protecting the battery core pack when the bottom case comes off or is broken due to impact loads during attachment or removal from electric vehicles, leading to inadequate support and exposure of the core pack.
Innovation Solution
A battery pack design with a battery core pack frame fixed to a positioning above the bottom case's upper end within the exterior case, preventing impact loads from being transmitted and ensuring the core pack remains supported and protected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the bottom case is used to cover the bottom surface of the battery core pack, then the battery core pack is protected from below, but the bottom case may come off or break due to impact load, leading to insufficient protection
Solution Approach 1:
The patent divides the protective structure into multiple independent components: the bottom case, the exterior case, and the battery core pack frame. Each component has a specific protective function, and the battery core pack frame is further divided into multiple fixing portions distributed at different locations. This segmentation ensures that if one component fails under impact, others continue to provide protection.
Solution Approach 2:
The battery core pack frame is fixed to the exterior case at multiple positions above the bottom case's upper end, creating a protective framework before impact occurs. This pre-established structural support system is designed to absorb and distribute impact loads, preventing the bottom case from bearing the full force of potential falls or collisions.
2Reliability
If the battery core pack frame is fixed to the exterior case, then the battery core pack is securely supported, but the fixing portion may be damaged by impact load transmitted through the bottom case
Solution Approach 1:
The patent positions the fixing portions in a specific spatial arrangement: they are located above the upper end of the bottom case rather than at the bottom case itself. This dimensional positioning creates a protective distance, so that impact loads must travel through the bottom case and exterior case structure before reaching the fixing portions, reducing the direct stress on the critical fixing connections.
3Strength
If the fixing portion is positioned above the bottom case, then impact load is prevented from transmitting to the fixing portion, but the structural complexity increases
Solution Approach 1:
The exterior case serves multiple functions: it provides the main structural housing for the battery core pack, supports the battery core pack frame through multiple fixing portions, and acts as a load-transmitting structure that protects the fixing portions from direct impact. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in structural complexity.
Data Source
AI summary
A battery pack comprises a battery core pack that has a plurality of battery cells held in a cell holder, and a case that accommodates the battery core pack. The case has an outer shell case that covers the side surface of the battery core pack, and a bottom case that covers the bottom surface of the battery core pack. A lower-side battery core pack frame that supports the battery core pack is secured in a lower-side securing groove provided to an inner wall of the outer shell case. The lower-side securing groove is disposed above the upper-end part of the bottom case attached to the lower-end part of the outer shell case.