Battery Pack Side-Frame Support for Module Load Distribution
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Solution Overview
Problem
Existing battery packs face challenges in distributing the load of battery modules efficiently, leading to potential sagging of the base plate and increased weight due to separate reinforcement structures, which complicates the structure and increases manufacturing costs.
Innovation Solution
A battery pack design featuring a base plate with a size smaller than the module mounting region, supported by side frames with extension parts that distribute the load, eliminating the need for additional reinforcement structures and integrating cooling channels for a compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base plate is thickened to withstand the load, then the load-bearing capacity is improved, but the pack weight increases reducing energy efficiency
Solution Approach 1:
The base plate is divided into a first base plate and a second base plate positioned at opposite sides of the center frame. This segmentation distributes the load-bearing function across multiple components, allowing each base plate to be thinner while collectively supporting the battery modules effectively.
Solution Approach 2:
The support structure transitions from a single-plane thick base plate to a three-dimensional configuration involving two base plates positioned at opposite sides of the center frame. This spatial arrangement distributes loads through multiple dimensions, reducing the thickness requirement of individual base plates while maintaining overall load-bearing capacity.
2Strength
If a separate lower reinforcement structure is installed to distribute the load, then the load distribution is improved, but the number of parts increases and manufacturing costs are increased
Solution Approach 1:
The reinforcement function is merged into the base plates themselves rather than being implemented as a separate lower reinforcement structure. The first and second base plates positioned at opposite sides of the center frame provide inherent load distribution capability, eliminating the need for additional reinforcement components.
Solution Approach 2:
The base plates serve multiple functions: they provide structural support, distribute loads from battery modules, and act as mounting surfaces. This multi-functionality eliminates the need for separate reinforcement structures that would otherwise be required for load distribution.
3Temperature
If the cooling panel and base plate are separately installed, then the cooling function is achieved, but the weight of the battery pack increases and the structure becomes complicated
Solution Approach 1:
The cooling channels are integrated directly into the base plates rather than using a separate cooling panel. The first cooling channels are formed in the first base plate and the second cooling channels are formed in the second base plate, merging the cooling function with the structural support function and simplifying the overall structure.
Data Source
AI summary
Discussed is a battery pack including a base plate on which battery modules are mounted; a front frame coupled to a front end of the base plate; a rear frame coupled to a rear end of the base plate; and side frames coupled to opposite sides of the base plate, respectively, wherein the base plate has a size that is less than a size of the module mounting region, and forms only a portion of the module mounting region, and wherein each of the side frames includes: a side wall part facing the battery modules, and a first extension part extending from a lower portion of the side wall part toward the base plate and coupled to a side surface of the base plate, and the first extension part supporting a load of the battery modules and forming the module mounting region together with the base plate.