Battery Pack Motion Prevention Unit and Spacer Design
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Solution Overview
Problem
Existing battery packs face challenges in maintaining the stability and preventing movement of battery cells, which can lead to degradation in performance due to vibrations and improper positioning, especially in applications requiring extended power delivery like electric vehicles.
Innovation Solution
The battery pack design incorporates a motion prevention unit and a stepped portion integrated into the case frame to securely hold battery cells in place, using spacers to accommodate adjacent cells and prevent vertical movement, while also allowing for efficient heat dissipation through strategically placed holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are arranged in a battery pack for extended power delivery, then output voltage and output current are increased, but movement and vibration of battery cells occur leading to instability
Solution Approach 1:
The battery pack is divided into modular units with individual spacers for each battery cell. Each spacer is a separate component that can be independently positioned to stabilize its corresponding battery cell, allowing the system to scale in power output while maintaining stability through modular repetition of stable sub-units.
Solution Approach 2:
Motion prevention units and spacers are introduced as intermediary components between the battery cells and the case frame. These intermediaries absorb and prevent the transmission of vibrations and movements, protecting the battery cells from destabilizing forces while allowing the battery pack to maintain high power output.
2Stability of the object's composition
If additional components are added to prevent battery cell movement, then stability is improved, but device complexity increases
Solution Approach 1:
The motion prevention units are integrated directly into the case frame structure, merging the stabilization function with the existing structural components. The spacers are designed to be simple insertable elements that combine positioning and stabilization functions in a single component, reducing overall system complexity while maintaining battery cell stability.
Solution Approach 2:
The spacers are designed with self-positioning features that allow them to automatically locate and stabilize battery cells without requiring complex adjustment mechanisms. The motion prevention units engage with the battery cells through simple geometric interlocking, allowing the components to self-assemble and self-stabilize the battery pack structure.
3Manufacturing precision
If spacers are used to accommodate battery cells, then positioning precision is improved, but manufacturing complexity increases
Solution Approach 1:
The spacers are designed with standardized dimensional parameters that can be easily manufactured using common machining processes. The motion prevention units utilize simple geometric parameters such as protrusion heights and engagement dimensions that are optimized for ease of manufacturing while providing precise positioning. The design allows for parameter adjustments to accommodate different battery cell sizes without changing the fundamental manufacturing approach.
Data Source
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AI summary
A battery pack includes a battery assembly including battery cells and spacers that are alternately arranged, a side plate extending across a side of the battery assembly, and a motion prevention unit protruding from the side plate toward the battery assembly so as to cover a portion of the battery assembly, the motion prevention unit being arranged on the spacers.