Battery Pack Frame Support for High-Density Electric Trucks
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Solution Overview
Problem
Vehicular battery packs face challenges in increasing energy density while maintaining stiffness, which is essential for extending cruising range and ensuring mountability, particularly in electric trucks where thickness and weight reduction are necessary without compromising structural integrity.
Innovation Solution
The implementation of a battery pack design featuring a surrounding frame that supports battery modules with L-shaped module-ends, a cooling bottom plate, and additional stiffener plates, which reduces the load on the bottom plate, increases energy density, and enhances stiffness through efficient heat management and structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of components is reduced to decrease volume and weight, then energy density is improved, but stiffness is worsened
Solution Approach 1:
The supporting function is segmented between the surrounding frame and the bottom plate. The surrounding frame with inwardly protruding extending portions bears the primary load of the battery module, while the bottom plate provides cooling and secondary support, allowing the bottom plate to be thinner without compromising overall stiffness.
Solution Approach 2:
The surrounding frame utilizes three-dimensional spatial arrangement with inwardly protruding extending portions that engage with L-shaped module-ends, creating a rigid spatial structure that provides stiffness without increasing the planar footprint or requiring thicker components.
2Weight of stationary object
If the thickness of the bottom plate is reduced to decrease weight, then energy density is improved, but load-bearing capacity is worsened
Solution Approach 1:
The load-bearing function is divided between the surrounding frame and the bottom plate. The surrounding frame's extending portions directly support the battery module weight, while the bottom plate handles cooling and distributed support, enabling weight reduction of the bottom plate without sacrificing overall load-bearing capacity.
Solution Approach 2:
The L-shaped module-ends act as intermediaries that transfer the battery module weight to the surrounding frame's extending portions, reducing the direct load on the bottom plate and enabling it to be thinner while maintaining load-bearing capacity through the frame structure.
3Strength
If the surrounding frame directly contacts the battery module to provide support, then stiffness is improved, but heat transfer to the frame is worsened
Solution Approach 1:
The L-shaped module-ends serve as intermediary contact elements between the battery module and the surrounding frame. These module-ends provide the necessary mechanical connection for stiffness while the gap between the module-end and extending portion minimizes direct thermal conduction path to the frame.
Solution Approach 2:
The contact interface is designed with localized engagement at the L-shaped module-ends with the extending portions, providing point-contact mechanical support for stiffness while maintaining a gap that limits thermal conduction. The local geometry optimizes the balance between mechanical support and thermal isolation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively increases energy density while ensuring the stiffness of the battery pack, contributing to extended cruising range and improved reliability, and allows for a thinner bottom plate, facilitating easier ground clearance in electric trucks.
Implementation Method 1
a cooling passage through which coolant flows
Implementation Method 2
the battery module can be cooled by the coolant that flows through the cooling passage inside the bottom plate
Data Source
AI summary
A vehicular battery pack includes a battery module including a plurality of battery cells that supply power to a motor for driving a vehicle, a bottom plate installed below the battery module, and a surrounding frame disposed on the bottom plate and surrounding the battery module. The surrounding frame includes an extending portion protruding inwardly and connected to the bottom plate. The battery module includes an L-shaped module-end facing the bottom plate and supported by the extending portion.