Battery Pack Frame Hinge Structure for Stronger Module Coupling
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Solution Overview
Problem
The existing battery packs lack sufficient durability due to inadequate coupling force between battery module frames, which can lead to frame separation and reduced reliability.
Innovation Solution
The battery pack design incorporates obliquely formed hinge parts and poles on the upper and side frames, with the hinge openings angled between perpendicular and parallel directions to enhance the coupling force, ensuring a secure fastening mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional perpendicular hinge fastening is used, then the structure is simple and easy to manufacture, but the coupling force between frames is insufficient leading to frame separation
Solution Approach 1:
The hinge opening is designed with an oblique angle rather than a perpendicular orientation. Specifically, the hinge opening forms an angle of 45-60 degrees with the normal line of the frame surface, creating an asymmetric fastening structure that generates both normal and friction forces, thereby significantly improving the coupling force between the upper frame and side frames while preventing frame separation.
2Reliability
If oblique hinge openings are formed, then the coupling force and durability are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The hinge opening angle is optimized to a specific range of 45-60 degrees relative to the frame normal. This parameter optimization ensures that the oblique fastening generates sufficient coupling force while remaining feasible for standard manufacturing processes. The specific angle range balances the need for improved durability with the practical constraints of manufacturing precision.
Data Source
AI summary
A battery pack includes: a battery module formed by stacking battery cells; an upper frame positioned on an upper surface of the battery module; a first side frame positioned on a first side surface of the battery module; and a second side frame positioned on a second side surface of the battery module facing the first side frame. The upper frame includes one or more first hinge parts positioned at one end of the upper frame. The first side frame includes one or more first poles positioned at an upper edge of the first side frame and fastened to the first hinge part. A first opening into which the first pole is inserted is formed in the first hinge part, and the first opening is formed obliquely so as to face between a direction perpendicular to the upper frame and a direction parallel to the upper frame.