Interlocking Battery Pack Frame for Cell Swelling Rigidity
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Solution Overview
Problem
Existing battery packs face challenges in efficiently connecting and securing multiple battery cells while maintaining structural integrity and preventing electrical and thermal interference, particularly in high-power applications like electric automobiles, where the connection force and rigidity of the pack can be compromised by cell swelling during charging and discharging.
Innovation Solution
A battery pack design featuring first and second frames that surround and interlock with battery cells, using complementary shapes and coupling blocks with insulating resin, along with spacers to manage cell expansion and enhance rigidity, and bus bar holders for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery cells are connected and bound in one unit, then the energy source capacity is improved, but the structural integrity is compromised due to cell swelling during charging and discharging
Solution Approach 1:
The frame is divided into multiple components including side portions, end portions, coupling blocks, and spacers. Each component performs a specific function: side portions provide lateral support, end portions secure the ends of battery cells, coupling blocks join frame components, and spacers manage cell expansion. This segmentation allows the structure to accommodate cell swelling while maintaining overall integrity.
Solution Approach 2:
Spacers are introduced as intermediary elements between adjacent battery cells. These spacers physically separate the cells and provide a buffer zone that absorbs the expansion forces during charging and discharging, preventing direct contact and potential damage between swelling cells.
2Stability of the object's composition
If a rigid frame structure is used to maintain structural integrity, then the stability is improved, but the connection force is compromised by cell swelling
Solution Approach 1:
The frame structure incorporates dynamic elements that can adapt to cell volume changes. The coupling blocks with insulating resin and the spacer assembly create a semi-flexible connection system that maintains structural stability while allowing for the dynamic expansion and contraction of battery cells during operation.
Solution Approach 2:
The frame uses composite construction combining rigid components (side portions, end portions) with flexible elements (insulating resin in coupling blocks, spacer materials). This composite approach allows the structure to maintain overall rigidity for stability while local flexible regions accommodate cell swelling without losing connection force.
3Object-affected harmful factors
If coupling blocks with insulating resin are used to connect frames, then the electrical insulation is improved, but the device complexity increases
Solution Approach 1:
The coupling block integrates multiple functions into a single component: mechanical connection between frame parts, electrical insulation through embedded insulating resin, and structural support. This merging eliminates the need for separate insulators and simplifies the overall connection structure despite the added insulation function.
Solution Approach 2:
The coupling block is designed as a multi-functional element that simultaneously provides structural connection, electrical insulation, and thermal management. This universal component reduces the total number of parts needed and simplifies assembly while addressing multiple concerns (electrical, mechanical, thermal) in one element.
Data Source
AI summary
A battery pack including a plurality of battery cells arranged in a first direction; and a first frame and a second frame each extending in the first direction with the plurality of battery cells therebetween, the first frame and the second frame surrounding outer surfaces of the plurality of battery cells and being fitted into each other in a second direction that intersects with the first direction.