Battery Pack Middle Cover Coupling Flange Vibration Control
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Solution Overview
Problem
Medium-sized battery packs for electric bicycles and motorcycles face issues with rechargeable battery cells vibrating inside the housing, which can lead to reduced performance and lifespan.
Innovation Solution
A battery pack design featuring a housing with a middle cover that includes a coupling flange and auxiliary couplers to securely contact the battery cells, preventing them from vibrating by fitting into the gap between the sidewalls and cells, and incorporating bus bar accommodating portions and gas release openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are accommodated in a housing without additional coupling structures, then the device complexity is reduced, but the battery cells will vibrate inside the housing leading to reduced performance and lifespan
Solution Approach 1:
The middle cover is divided into a body portion and a coupling flange portion, where the coupling flange extends from the body to specifically engage with battery cells. This segmentation allows the vibration prevention function to be localized to specific structural elements rather than requiring the entire housing to be complex.
Solution Approach 2:
The coupling flange acts as an intermediary element between the housing and battery cells, providing a dedicated coupling interface that secures cells without requiring complex modifications to either the housing or the cells themselves.
2Reliability
If coupling structures are added to prevent battery cell vibration, then the reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The coupling flange is integrated with the middle cover body to form a single component, eliminating the need for separate coupling parts and reducing assembly steps. The flange and body are manufactured together as one piece, simplifying the manufacturing process while providing effective vibration prevention.
Solution Approach 2:
The middle cover serves multiple functions: it provides structural support, electrical insulation, and battery cell securing through the coupling flange. This multi-functionality reduces the need for additional separate components, simplifying both manufacturing and assembly.
Data Source
AI summary
A battery pack includes a battery module including a plurality of battery cells; a housing accommodating the battery cells, the housing having a bottom plate and a plurality of side walls extending from the bottom plate; and a middle cover covering the battery module, the middle cover having a body and a coupling flange extending away from the body and located between one of the side walls and the battery module.