Battery Pack Side Plate Coupling Structure for Stacking Alignment
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Solution Overview
Problem
Existing battery pack and module configurations struggle to efficiently combine multiple battery packs for increased output and capacity, particularly in applications requiring high power, such as electric vehicles, where traditional methods fail to provide a robust and adjustable coupling structure for vertical and horizontal stacking.
Innovation Solution
A battery pack and module design featuring a coupling structure with bent side plates, penetrating and combining coupling members, and position determination portions, allowing for secure stacking and alignment of battery packs in both vertical and horizontal orientations, with adjustable coupling positions to accommodate processing errors and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery pack configurations are used, then the structure is simple, but the coupling strength and structural stability between stacked battery packs are insufficient
Solution Approach 1:
The side plate is divided into multiple coupling portions (first coupling portions at upper edges and second coupling portions at lower edges) that can independently engage with adjacent battery packs. This segmentation allows the coupling structure to distribute mechanical loads across multiple points, significantly enhancing the overall coupling strength between stacked battery packs while maintaining a modular design that doesn't excessively increase complexity.
Solution Approach 2:
The coupling portions are bent to extend away from the battery cells, creating curved engagement surfaces rather than flat contacts. This curvature allows for better mechanical interlocking between adjacent battery packs, increasing coupling strength through geometric interlocking while the bent structure naturally accommodates minor misalignments without requiring complex adjustment mechanisms.
2Manufacturing precision
If fixed coupling positions are used, then the manufacturing process is simple, but the alignment precision between stacked battery packs cannot accommodate processing errors
Solution Approach 1:
The coupling portions are designed with adjustable engagement parameters - the bent coupling portions can engage at slightly different positions along their length, allowing the assembly to accommodate processing tolerances. The elongated slot in the installation hole provides parameter adjustment in the horizontal direction, while the vertical stacking allows parameter adjustment in the vertical direction, achieving high alignment precision without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The coupling structure transitions from a rigid fixed-position design to a dynamic adjustable design where the bent coupling portions can be positioned at optimal engagement points during assembly. The combination of vertical stacking flexibility and horizontal slot adjustment creates a dynamic assembly process that can adapt to actual component variations, ensuring precise alignment while maintaining ease of manufacture.
3Reliability
If multiple coupling members are used, then the reliability of the coupling structure increases, but the device complexity increases
Solution Approach 1:
The penetrating coupling member serves multiple functions simultaneously: it mechanically connects adjacent battery packs, provides structural support for the stacked configuration, and enables the adjustable positioning capability through its interaction with the elongated slot. The combining coupling member similarly serves as both a structural connector and a positioning element. This multi-functionality increases reliability through redundant load paths while avoiding the need for separate dedicated components for each function.
Solution Approach 2:
The coupling structure merges the penetrating coupling member and combining coupling member into a single integrated engagement system where both members work together to achieve secure connection. The bent coupling portions are merged into the side plate structure rather than being separate components, reducing the total number of parts while maintaining coupling reliability through the integrated design.
4Power
If battery packs are stacked for high power applications, then the output and capacity increase, but the structural stability and coupling security become challenging
Solution Approach 1:
The coupling structure utilizes both vertical and horizontal dimensions for stability. Vertically, multiple coupling portions engage between adjacent battery packs in the stack. Horizontally, the elongated slot allows for lateral adjustment and engagement. This two-dimensional coupling approach creates a stable stacked structure capable of supporting high power applications by distributing mechanical stresses across multiple spatial dimensions rather than relying on single-point connections.
Data Source
AI summary
A battery pack includes first and second end plates spaced apart from each other along a first direction, a plurality of battery cells aligned along the first direction between the first and second end plate, each battery cell having an electrode terminal thereon, and a side plate extending along side surfaces of the battery cells and coupled to the first and second end plates, the side plate having first coupling portions along upper edges of the side plate, the first coupling portions being bent to extend away from the battery cells, and second coupling portions along lower edges of the side plate, the second coupling portions being bent to extend away from the battery cells and to face the first coupling portions, the second coupling portions being positioned to at least partially correspond to respective first coupling portions.