Battery Pack Retention Bar Layout for Uniform Module Height
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Solution Overview
Problem
The challenge is to maintain uniform height of battery modules within a pack case and prevent assembly deformation due to swelling, which affects electrical connections and thermal resistance, especially when using small battery modules with uneven heights.
Innovation Solution
A battery pack design featuring retention bars that extend along the stacking direction of the modules, coupled to the pack case to press the upper surfaces of the modules, ensuring uniform height and stability, and an adhesive resin layer to secure the modules while allowing for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive resin is applied to fixate battery modules in the pack case, then the battery modules can be secured in position, but the height of the battery modules becomes uneven due to non-uniform adhesive distribution
Solution Approach 1:
A lower support plate is introduced as an intermediary component between the pack case and the battery modules. The support plate provides a flat, rigid base that ensures uniform height and stable fixation of the battery modules without relying on non-uniform adhesive resin application. This mediator transfers the load uniformly across all modules, solving both the fixation stability and height uniformity problems simultaneously.
2Adaptability or versatility
If small battery modules are used to increase flexibility in pack configuration, then the pack can be more adaptably configured, but the modules become lightweight and prone to height variation and assembly deformation
Solution Approach 1:
The lower support plate serves as a mediator that provides uniform mechanical support to lightweight small battery modules. By distributing the support force evenly across all modules through the rigid plate, height variation is prevented while maintaining the adaptability benefits of using smaller, more flexible module sizes for pack configuration.
Solution Approach 2:
The support plate changes the mechanical parameter of support distribution from point-contact adhesive fixation to surface-contact uniform support. This parameter change in the support mechanism ensures that lightweight modules maintain uniform height and proper positioning throughout the pack assembly.
3Reliability
If battery modules are allowed to swell during operation, then the battery can maintain its chemical function, but the assembly deforms and electrical connections are affected
Solution Approach 1:
The upper pressing plate is positioned and configured to apply predetermined pressing force on the battery modules from above. This beforehand cushioning mechanism compensates for the swelling that occurs during battery operation, maintaining assembly shape stability and preventing deformation of electrical connections while allowing the batteries to maintain their chemical function.
Solution Approach 2:
The pressing force parameter is applied uniformly across the battery modules to counteract the volume expansion during swelling. By controlling this mechanical parameter, the system maintains electrical connection integrity and assembly stability while the batteries undergo their normal chemical operation and swelling cycles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design maintains uniform module heights, facilitates easier welding of electronic components, prevents assembly deformation due to swelling, and enhances internal space utilization by minimizing fastening points, improving coupling rigidity and thermal management.
Implementation Method 1
an adhesive resin layer to secure the modules
Implementation Method 2
retention bars that extend along the stacking direction of the modules, coupled to the pack case to press the upper surfaces of the modules
Data Source
AI summary
The battery pack includes a plurality of battery module accommodating a plurality of battery cells; a pack case in which the plurality of battery modules are stacked in a horizontal direction; and a retention bar extending along the stacking direction of the battery modules and is coupled to the pack case while pressing an upper surface of opposite sides of the stacked battery modules.