Battery Pack Reinforcement Layout for Casing Rigidity
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Solution Overview
Problem
Battery packs in electric vehicles face reduced rigidity due to elongated casings, leading to potential deformation and collision with cell modules during vehicle collisions, which can damage the battery cells and associated devices.
Innovation Solution
A battery pack configuration with two cell modules arranged side by side, a reinforcement structure along the casing, and a fastening bracket system that enhances the rigidity of the casing, including a protector to prevent direct contact between the casing and cell modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cell modules are arranged side by side in the longitudinal direction to fit the installation space, then space utilization is improved, but the casing rigidity decreases leading to potential deformation and collision with cell modules during vehicle collisions
Solution Approach 1:
The battery pack is divided into multiple cell modules arranged side by side in the longitudinal direction, allowing efficient space utilization while maintaining structural integrity through modular design. Each cell module is independently housed, enabling the casing to be segmented into manageable sections that can better resist deformation forces.
Solution Approach 2:
The reinforcement structure is added in the width direction (second direction) to strengthen the casing that is primarily elongated in the longitudinal direction. This dimensional addition provides structural support perpendicular to the main elongation, preventing deformation and collision during vehicle collisions while maintaining the space-efficient longitudinal arrangement.
2Volume of moving object
If the casing is elongated in one direction to accommodate multiple cell modules, then space utilization is improved, but the rigidity decreases making the casing susceptible to deformation during collisions
Solution Approach 1:
The battery pack configuration segments the elongated space into multiple cell modules with intermediate spaces between them. This segmentation prevents the continuous elongated structure from deforming as a single unit, thereby maintaining stability while utilizing the elongated space efficiently.
Solution Approach 2:
A reinforcement structure extending in the width direction (second direction) is introduced to provide transverse support to the longitudinally elongated casing. This dimensional addition stabilizes the casing composition by preventing lateral deformation and collapse during collision events.
3Strength
If a reinforcement structure is added to prevent casing deformation, then casing rigidity is improved, but the device complexity increases
Solution Approach 1:
The reinforcement structure is merged with the existing casing structure, forming an integrated assembly. The reinforcement plates are positioned within the intermediate spaces between cell modules and are structurally combined with the casing walls, creating a unified structure that enhances rigidity without adding separate complex components.
Solution Approach 2:
The intermediate spaces between cell modules serve multiple functions: they provide structural reinforcement through the added plates, act as buffer zones to prevent cell module collision, and maintain spacing for thermal management. This multi-functionality reduces the need for additional dedicated reinforcement components, simplifying the overall structure.
Data Source
AI summary
The battery pack comprises: two cell modules arranged side by side in a first direction with an intermediate space therebetween, each of the two cell modules having a longitudinal direction parallel to the first direction and a lateral direction parallel to a second direction; a casing that houses the two cell modules, the casing having a main wall, which is a front wall or a rear wall spaced apart from the two cell modules in the second direction; and a reinforcement having at least a first wall disposed along the main wall, wherein the reinforcement overlaps the intermediate space and a part of each of the two cell modules in a front view.