Battery Pack Housing Structure With Reinforcing Beams
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Solution Overview
Problem
Existing battery packs are heavy due to their structural design, which is costly and inefficient to produce, particularly when using lightweight materials to reduce weight.
Innovation Solution
The battery pack design incorporates reinforcing beams and a lower housing with a stepped structure, where battery cells are arranged in rows, contacting side plates or beams, enhancing strength and reducing weight while maintaining production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight materials such as carbon fiber are used for the lower housing to reduce weight, then the overall weight of the battery pack is reduced, but the cost increases and production efficiency decreases
Solution Approach 1:
The patent employs composite material construction by integrating reinforcing beams (made of metal or other strong materials) with the lightweight housing material. This composite approach allows the housing to maintain lightweight properties while the integrated reinforcing beams provide the necessary structural strength, thereby achieving weight reduction without compromising manufacturing feasibility or structural integrity
2Weight of moving object
If lightweight materials such as carbon fiber are used for the lower housing to reduce weight, then the overall weight of the battery pack is reduced, but the production cost increases
Solution Approach 1:
The patent employs composite material construction by integrating reinforcing beams (made of metal or other strong materials) with the lightweight housing material. This composite approach allows the housing to maintain lightweight properties while the integrated reinforcing beams provide the necessary structural strength, thereby achieving weight reduction without compromising manufacturing feasibility or structural integrity
3Strength
If end plates are used for battery modules to resist expansion force, then structural strength is maintained, but the overall weight of the battery pack increases
Solution Approach 1:
The patent merges the function of the end plates with the reinforcing beams of the lower housing. The reinforcing beams are integrated into the housing structure and directly contact the battery cells to resist expansion forces. This merging eliminates the need for separate end plates, thereby maintaining structural strength while reducing overall weight
4Strength
If reinforcing beams are added to the lower housing to increase strength, then structural strength is improved, but the weight of the lower housing increases
Solution Approach 1:
The patent applies local quality by strategically placing reinforcing beams only at specific locations where structural strength is most needed - specifically at the side plates and where battery cells make contact. This localized reinforcement provides necessary strength while minimizing the addition of weight compared to a complete housing redesign
Data Source
AI summary
A battery pack, including: a plurality of battery cells, where each of the plurality of battery cells includes a top cover and a case, the top cover is hermetically connected on a top of the case, the case includes opposite first surfaces and opposite second surfaces, and an area of each first surface is larger than that of each second surface; and a lower housing, including a bottom plate disposed at a bottom, side plates disposed at sides, and an opening is disposed at an upper part, each of a pair of opposite side plates of the lower box is disposed with a reinforcing beam. At least one first surface of the plurality of battery cells is in contact with a side plate of the lower housing or the reinforcing beam.