Rechargeable Battery Pack Integrated Housing Design
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Solution Overview
Problem
Conventional rechargeable battery packs require a module frame, increasing the number of parts, material costs, weight, and manufacturing complexity due to the separate assembly of battery modules and pack housings.
Innovation Solution
The solution involves directly inserting and fixing barriers between unit cells into a pack housing, eliminating the need for a module frame by using a tight-fitting structure, where the barriers are coupled to each other and the housing, reducing the number of parts and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a module frame is used to assemble battery modules and pack housings separately, then the structural integrity and assembly flexibility are improved, but the number of parts, material costs, weight, and manufacturing complexity increase
Solution Approach 1:
The patent merges the module frame and pack housing into a single integrated pack housing structure. The pack housing directly accommodates multiple battery cells with built-in positioning features and structural support, eliminating the separate module frame. This integration reduces the number of parts while maintaining structural integrity through the unified design that provides both containment and organizational functions.
2Adaptability or versatility
If a module frame is used with separate assembly of battery modules and pack housings, then assembly flexibility is improved, but manufacturing complexity and process complication increase
Solution Approach 1:
The patent combines the functions of the module frame and pack housing into a single integrated structure that is manufactured as one piece. This unified pack housing includes built-in features for battery cell positioning, electrical insulation, and structural support, eliminating the need for separate module frame assembly and reducing manufacturing process complexity.
3Strength
If a module frame is used in the battery pack structure, then structural support is improved, but weight increases
Solution Approach 1:
The patent integrates the structural support functions previously provided by the separate module frame into the pack housing itself. The pack housing is designed with reinforced structures, ribs, and integrated positioning features that provide the necessary structural support while eliminating the weight of the redundant module frame.
4Reliability
If barriers are separately assembled between unit cells in a module frame, then electrical insulation is improved, but the number of parts and assembly steps increase
Solution Approach 1:
The patent integrates the electrical insulation barriers into the pack housing structure itself. The pack housing includes built-in insulating features, positioning ribs, and structural elements that serve both mechanical support and electrical insulation functions, eliminating the need for separate barrier components and reducing the total number of parts.
Data Source
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AI summary
A rechargeable battery pack including unit cells each including a rechargeable battery, barriers coupled to each other at an outer circumference of the unit cells and each located between respective ones of the unit cells, and a pack housing that accommodates the unit cells and the barriers, and that is coupled to the barriers by tight-fitting.