Battery Pack Reinforcement Layout for Strength and Thermal Insulation
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Solution Overview
Problem
Conventional battery packs in electric vehicles suffer from insufficient structural strength and protection, leading to potential deformation and safety issues under stress.
Innovation Solution
A battery pack design incorporating a tray with a reinforcing member and thermal insulation member, featuring reinforcing portions and thermal insulation protrusions, which enhance structural strength, vibration resistance, and thermal insulation, while improving the battery pack's ability to withstand external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic material or thin-walled stamped metal is used for the upper cover, then manufacturing cost and ease of manufacture are improved, but structural strength and protection strength at the bottom of the battery pack deteriorate
Solution Approach 1:
The patent employs composite material construction by combining the tray (bottom plate + side beams + support beams) with the upper cover as integrated load-bearing structures. This composite framework provides enhanced structural strength and rigidity compared to conventional single-material designs, while maintaining manufacturing feasibility through modular assembly of the tray and upper cover components.
Solution Approach 2:
The patent introduces a three-dimensional framework structure with the tray forming a rigid base and the upper cover providing top protection, creating a spatial load-bearing system. This dimensional approach distributes mechanical stresses across multiple structural elements rather than relying on a single thin-walled component, thereby improving overall structural strength.
2Ease of operation
If the upper cover is installed on the tray, then assembly completeness is improved, but structural strength in the width direction of the tray deteriorates
Solution Approach 1:
The battery pack structure is segmented into distinct functional components: the tray (comprising bottom plate, side beams, and support beams) and the upper cover. This segmentation allows for independent optimization of each component's structural properties while maintaining ease of assembly through standardized connection interfaces.
Solution Approach 2:
The tray and upper cover are designed as multi-functional components that simultaneously provide structural support, protection, and assembly integration. The tray serves as both the base structure and mounting platform for battery modules, while the upper cover provides both protection and structural rigidity, achieving multiple functions without compromising structural strength.
3Device complexity
If no additional protection structures are added, then device complexity is reduced, but protection strength and vibration resistance deteriorate
Solution Approach 1:
The patent merges the protective function with the structural framework by integrating the tray and upper cover as load-bearing components rather than adding separate protection elements. This merging approach enhances protection strength and vibration resistance while avoiding excessive increase in device complexity, as the protective structures are already part of the basic battery pack assembly.
Data Source
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AI summary
A vehicle (1000) that includes a battery pack (100) is provided. The battery pack (100) includes a tray (20), a plurality of battery cells (23), a reinforcing member (30), and a thermal insulation member (40). The tray (20) includes a bottom plate (22), a side beam (28), and at least one support beam (21), the bottom plate (22) and the side beam (28) enclose an accommodating cavity (27), and the support beam (21) is disposed in the accommodating cavity (27). The plurality of battery cells (23) are disposed in the tray (20). The reinforcing member (30) is disposed in the accommodating cavity (27), the reinforcing member (30) is disposed at a bottom of the bottom plate (22), the reinforcing member (30) includes a plurality of reinforcing portions (31), the plurality of reinforcing portions (31) are spaced apart, and at least one reinforcing portion (31) is located at the support beam (21) and extends to a position below the battery cell (23). At least one thermal insulation protrusion (41) is disposed on the thermal insulation member (40), and the thermal insulation protrusion (41) is located in a gap between two adjacent reinforcing portions (31).