Battery Pack Module Assembly With Mediated Vertical Connections
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Solution Overview
Problem
The accumulation of tolerances in the multi-stage structure of battery packs makes it difficult to assemble components effectively, particularly in battery packs with stacked battery modules and cooling plates.
Innovation Solution
A battery pack design that includes first and second connection portions with mediation and insertion members to connect adjacent battery modules vertically, and reinforcement connection members to stabilize the assembly, while maintaining spacing from cooling plates to accommodate manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If battery modules and cooling plates are stacked in a multi-stage structure, then cooling effectiveness is improved, but assembly difficulty increases due to tolerance accumulation
Solution Approach 1:
A mediation member is introduced between adjacent battery modules to serve as an intermediary component. This mediation member includes a through-hole that accommodates an insertion member, enabling flexible adjustment during assembly. The mediation member absorbs tolerance variations between stacked components, allowing the multi-stage structure to be assembled easily while maintaining proper spacing and alignment between battery modules and cooling plates
Solution Approach 2:
The connection structure is divided into multiple functional parts: a mediation member providing spacing and alignment, and an insertion member penetrating through the mediation member to secure the connection. This segmentation allows each component to address specific assembly challenges independently, with the mediation member handling tolerance accommodation and the insertion member providing mechanical fastening
Data Source
AI summary
A battery pack includes two or more battery modules stacked in a vertical direction in which each battery module includes a plurality of battery stacks disposed in a horizontal direction, cooling plates provided between the two or more battery modules, and a first connection portion connecting the two battery modules provided adjacent to each other in the vertical direction, in which the first connection portion includes a first mediation member provided between the two battery modules provided adjacent to each other in the vertical direction, and an insertion member penetrating the first mediation member and one side of each of the two battery modules provided adjacent to each other in the vertical direction, and in which the insertion member is spaced apart from the cooling plate.