Battery Pack Clamp and Plate Structure for Impact Isolation
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Solution Overview
Problem
Existing battery packs in electric vehicles face challenges in effectively alleviating impact transmitted to battery cells when subjected to external forces, particularly when mounted in an inverted state, which can lead to damage and compromise safety.
Innovation Solution
A battery pack design incorporating a battery housing, pack cover, and a plate with a clamp member that spaces battery cells apart from the pack cover using a clamp member and/or a plate structure with extension parts or cover contact parts to absorb and distribute impact, enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are arranged closely in the battery housing to maximize space utilization, then productivity and space efficiency are improved, but the ability to alleviate impact transmitted to battery cells deteriorates
Solution Approach 1:
A plate structure is introduced as an intermediary component between the battery cells and the pack cover. The plate includes a cell contact part that contacts the battery cells and a cover contact part that contacts the pack cover, acting as a mediator to absorb and distribute impact forces before they reach the battery cells, thus resolving the contradiction between close arrangement and impact protection
2Reliability
If a clamp member with extension parts is added to space battery cells apart from the pack cover to improve impact protection, then safety is improved, but device complexity increases
Solution Approach 1:
The clamp member integrates multiple functions into a single component: it includes a base part that contacts the pack cover, coupling parts that extend toward the battery cells, and hooks that engage with the battery cell tabs. This merging of functions (support, spacing, and securing) into one component achieves impact protection without proportionally increasing overall structural complexity
3Object-affected harmful factors
If the plate structure is designed with both cell contact part and cover contact part to absorb impact, then impact protection is improved, but manufacturing complexity increases
Solution Approach 1:
The plate is segmented into distinct functional regions: a cell contact part that contacts the battery cells, a cover contact part that contacts the pack cover, and intermediate portions that connect them. This segmentation allows each region to be optimized for its specific function while maintaining manufacturability through standard forming processes
Data Source
AI summary
An embodiment battery pack includes a battery housing defining a receiving space, battery cells accommodated in the receiving space and arranged in a first direction, a pack cover covering first sides of the battery cells facing in a second direction crossing the first direction, a plate disposed between the battery cells, and a clamp member, wherein a partial region of the clamp member is disposed between the plate and the pack cover in the second direction and is in contact with the plate.