Battery Pack Module Mounting for Compact High-Energy Layouts
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Solution Overview
Problem
Conventional battery packs face challenges in achieving a compact structure and high energy density due to the need for additional mounting space and structures like separate mounting plates, which increase weight and reduce energy efficiency.
Innovation Solution
A battery pack design featuring a pack housing that supports multiple battery modules, with mounting units pressing the modules toward the housing using pressing bars and bolts, eliminating the need for additional mounting space and separate plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate mounting plate is added to fix battery modules, then the battery modules can be securely fixed, but the weight of the battery pack increases and energy density decreases
Solution Approach 1:
The mounting plate is merged with the battery module structure itself. The side plates of the battery module are designed with protruding ends that directly engage with the pack housing, eliminating the need for a separate mounting plate. This integration reduces the number of components and overall weight while maintaining secure fixation.
Solution Approach 2:
The side plates of the battery module serve dual functions: they provide structural support for the battery cells and simultaneously act as mounting structures for securing the module to the pack housing. This multi-functionality eliminates the need for dedicated mounting plates.
2Reliability
If a separate mounting plate is added to fix battery modules, then the battery modules can be securely fixed, but the energy density of the battery pack decreases
Solution Approach 1:
The mounting function is merged into the battery module's side plates, eliminating the need for additional mounting plates. This reduces the non-active material volume in the battery pack, thereby increasing the proportion of active battery materials and improving energy density.
Solution Approach 2:
The separate mounting plate is extracted/removed from the system. By eliminating this non-essential component and integrating its function into the existing side plates, the battery pack achieves higher energy density without compromising fixation stability.
3Reliability
If additional mounting space is provided in the pack housing, then the battery modules can be fixed, but the size of the pack housing increases
Solution Approach 1:
The mounting space is merged with the existing battery module structure. The protruding ends of the side plates utilize the space between battery modules, eliminating the need for additional dedicated mounting space in the pack housing and maintaining a compact overall size.
4Reliability
If a fixing frame with presser pieces is used to fix battery stacks, then the battery stacks can be secured, but the device complexity increases
Solution Approach 1:
The fixing frame and presser pieces are merged into the side plates of the battery modules. The side plates with protruding ends directly engage with the pack housing, eliminating the need for a separate fixing frame structure and reducing overall device complexity.
Solution Approach 2:
The complex fixing frame structure is extracted/removed from the system. The simplified mounting approach using protruding ends of side plates achieves the same fixation function with significantly reduced structural complexity.
Data Source
Figure 1
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AI summary
A battery pack according to an embodiment of the present disclosure includes a plurality of battery modules each including at least one battery cell, a pack housing supporting the plurality of battery modules, and a plurality of mounting units coupled to the pack housing, located between the plurality of battery modules, and configured to press the plurality of battery modules toward the pack housing.