Two-Layer Battery Pack Assembly with Integrated Connection Members
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Solution Overview
Problem
Existing battery packs face challenges in achieving a compact, stable structure for installation in limited spaces like vehicles, with complex assembly processes and increased volume and weight due to the need for multiple members for mechanical fastening and electrical connection, and inadequate mechanical strength leading to potential separation of thermally welded regions during charge and discharge.
Innovation Solution
A battery pack design featuring a two-layer structure of stacked battery modules with connection members, side support members, and insulation to simplify assembly, enhance stability, and reduce the number of members required for mechanical fastening and electrical connection, using high-strength cell covers to prevent expansion and contraction-induced separation, and incorporating a battery management system for safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple members are used for mechanical fastening and electrical connection, then the battery pack achieves stable structure and reliable electrical connection, but the device complexity and number of parts increase
Solution Approach 1:
The patent combines mechanical fastening and electrical connection functions into a single integrated connection member. This member simultaneously provides structural support through its rigid frame structure and electrical connection through conductive elements, eliminating the need for separate mechanical fasteners and electrical connectors. The integration reduces part count while maintaining both mechanical stability and electrical reliability.
Solution Approach 2:
The connection member is designed with multi-functionality, serving as both a structural support element and an electrical conductor. The rigid frame provides mechanical fastening and positioning, while integrated conductive elements establish electrical connections between battery modules. This universal design allows one component to fulfill multiple functions that previously required separate parts.
2Ease of manufacture
If traditional battery modules with low mechanical strength are used, then the manufacturing cost is reduced, but the thermally welded regions separate during charge and discharge
Solution Approach 1:
The rigid frame structure of the connection member is designed to preemptively counteract the expansion and contraction forces that occur during battery charge and discharge cycles. The frame provides preemptive mechanical support that prevents the thermally welded regions from separating, addressing the structural weakness before it can cause failure. This prior cushioning approach maintains structural integrity without requiring more expensive battery modules.
3Reliability
If the battery pack volume is increased to accommodate multiple members, then the structural stability is improved, but the space occupation increases
Solution Approach 1:
By merging mechanical support and electrical connection functions into a single integrated member, the patent eliminates the volume occupied by multiple separate components. The unified connection member achieves the same structural stability as multiple separate members would provide, while occupying less space. This integration allows the battery pack to maintain structural integrity without increasing overall volume.
4Reliability
If complex assembly processes are used to install multiple members, then the structural stability is ensured, but the assembly time and manufacturing complexity increase
Solution Approach 1:
The integration of multiple functions into a single connection member dramatically simplifies the assembly process. Instead of installing multiple separate mechanical fasteners and electrical connectors, workers only need to install one unified component. This reduces assembly steps, decreases assembly time, and lowers manufacturing complexity while maintaining the structural stability that would otherwise require multiple components to achieve.
Data Source
AI summary
Disclosed herein is a battery pack including (a) a module assembly including two or more battery modules, each of which includes a chargeable and dischargeable battery cell, the battery modules being stacked to have a two layer structure including an upper layer and a lower layer while being in contact with each other in a lateral direction, (b) a first upper layer connection member and a second upper layer connection member mounted at the upper layer module assembly, (c) a first lower layer connection member and a second lower layer connection member mounted at the lower layer module assembly, (d) a pair of side support members, (e) insulation members mounted at interfaces between the sides of the upper and lower layer module assemblies and the side support members, and (f) a first lower end support member and a second lower end support member.