Battery Pack Reverse Assembly With Rigid Beam and Integrated Cooling
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Solution Overview
Problem
Conventional battery pack assembly structures lead to decreased energy density and inefficient space utilization due to unnecessary gaps and complex bolt-fastening structures, which complicate the assembly process and interfere with cooling systems.
Innovation Solution
A battery pack design featuring a pack case with a pack tray and cover, where battery modules are fixed with a rigid beam and cooling system integrated into the module case, allowing for simultaneous electrical connection and mechanical fixation, and utilizing a top cover and base plate for efficient coolant circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery modules are fixed to the pack tray using bolt fastening at four corners, then mechanical fixation is achieved, but space utilization decreases due to unnecessary gaps and space occupancy of cross beams
Solution Approach 1:
The patent merges the fixation function and support function into a single integrated structure. The support plate is integrally formed with the pack tray, eliminating the need for separate cross beams and multiple bolts. This integration removes unnecessary gaps and optimizes space utilization while maintaining mechanical fixation capability.
Solution Approach 2:
The support plate serves multiple functions simultaneously: it provides mechanical support for battery modules, acts as a fixation structure, and optimizes space utilization. By combining multiple functions into a single component, the patent eliminates the need for separate cross beams and reduces the number of fastening points.
2Strength
If cross beams are added to the pack tray to increase rigidity, then mechanical rigidity is improved, but energy density decreases due to space occupancy and gaps
Solution Approach 1:
The support plate is integrally formed with the pack tray, creating a unified rigid structure. This integration eliminates the need for separate cross beams while maintaining or enhancing mechanical rigidity. The eliminated space previously occupied by cross beams and gaps is now available for battery modules, thereby improving energy density.
3Reliability
If multiple bolts are used for fixing battery modules, then secure mechanical connection is achieved, but assembly complexity increases
Solution Approach 1:
The patent extracts and eliminates unnecessary fastening points from the assembly structure. By using an integrally formed support plate, the number of bolts required for fixation is reduced, simplifying the assembly process while maintaining reliable mechanical connection through the integrated structure.
4Ease of manufacture
If bolt fastening structure is used for fixing battery modules, then mechanical fixation is achieved, but cooling system configuration becomes complicated
Solution Approach 1:
The support plate is integrally formed with the pack tray, creating a unified structure that simplifies cooling system configuration. This integration eliminates interference with cooling water input/output lines and allows for more straightforward coolant flow paths, reducing the complexity of the cooling system while maintaining effective thermal management.
Data Source
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AI summary
Disclosed is a battery pack, which includes a plurality of battery modules and a pack case in which the battery modules are fixedly installed, the battery case includes a pack tray located at a lower portion of the battery modules, and a pack cover coupled with the pack tray to cover the battery modules, and each of the battery modules is fixedly coupled to the pack cover and includes battery cells arranged in one direction, a module case for accommodating the battery cells in an inner space thereof, and a rigid beam disposed between the battery cells inside the module case.