Battery Pack Module Connection for Rigidity and Warpage Control
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Solution Overview
Problem
Existing battery packs face challenges in maintaining structural rigidity and preventing warpage and module separation due to the increasing weight and capacity of battery modules, which can lead to vibration and safety issues in electric vehicles.
Innovation Solution
A battery pack design where multiple battery modules are connected using a plate-like connection member with a plane portion parallel to the module arrangement direction, engaging with adjacent modules to distribute weight evenly and enhance rigidity, while a flange portion is fixed to the battery case to prevent warpage and module separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are arranged horizontally next to one another in the battery case, then the battery pack can accommodate multiple modules, but the increasing weight and capacity of battery modules cause warpage and structural rigidity issues
Solution Approach 1:
The battery pack structure is segmented into multiple battery modules arranged in a matrix pattern, with each module independently connected to the battery case through connection members. This segmentation allows the system to accommodate multiple modules while distributing the weight load to individual connection points, preventing overall structural warpage.
Solution Approach 2:
The connection members extend in the vertical direction (thickness direction of the battery case) to connect the battery modules to the battery case. This vertical dimension provides structural support and rigidity, counteracting the warpage caused by horizontal arrangement of multiple heavy modules.
2Quantity of substance
If battery modules are arranged horizontally next to one another, then more modules can be stored, but vibration and module separation occur due to insufficient connection
Solution Approach 1:
The connection members are pre-installed to connect adjacent battery modules to each other and to the battery case before the modules are subjected to vibration or operational stresses. This preliminary connection ensures that modules are securely bound together, preventing separation during vehicle operation.
3Ease of manufacture
If traditional connection methods are used, then assembly is simple, but the battery pack lacks sufficient rigidity and durability under increased module weight
Solution Approach 1:
The connection members serve dual functions: they connect adjacent battery modules to each other horizontally, and simultaneously connect these modules to the battery case vertically. This merging of connection functions creates a integrated structural framework that enhances overall rigidity without adding separate connection components.
Data Source
AI summary
A battery pack includes a first battery module, a second battery module, and a connector. The first battery module includes laminated cells and has a first outer surface. The second battery module includes laminated cells and has a second outer surface. The second battery module is provided adjacent to the first battery module. The connector has a plane surface and is provided on the first battery module and the second battery module such that the plane surface of the connector opposes the first outer surface and the second outer surface to connect the first battery module and the second battery module.