Modular Battery Pack with Side Support and Coupling for External Mounting
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Solution Overview
Problem
Existing battery packs face challenges in easy assembly, extension, and structural stability, with complex assembly processes and high manufacturing costs, along with difficulties in modifying the structure to accommodate increased capacity and ensuring safety against charge/discharge cycles and potential malfunctions.
Innovation Solution
A battery pack design featuring a module assembly with stacked unit cells, side support members, coupling members, a base plate with fastening parts, and a sheathing cover that allows for easy assembly, extension, and secure mounting to external structures, while incorporating features like ventilation and reinforcement for stability and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a plurality of battery modules is used to constitute the battery pack, then the output and capacity of the battery pack can be increased, but the assembly process becomes very complicated requiring multiple members such as bus bars or power connection cables for mechanical fastening and electrical connection
Solution Approach 1:
The patent merges mechanical fastening and electrical connection functions into a single integrated battery module structure. The battery modules are designed with built-in electrical connections and mechanical coupling features, eliminating the need for separate bus bars or power connection cables, thereby simplifying the assembly process while maintaining increased capacity
Solution Approach 2:
The battery modules are designed as universal units that simultaneously provide mechanical support, electrical connection, and thermal management functions. Each module is configured to perform multiple functions, reducing the number of separate components needed and simplifying the overall assembly process
2Quantity of substance
If the battery pack structure is modified to extend capacity, then the capacity can be increased, but it is necessary to add a plurality of parts thereby increasing manufacturing cost
Solution Approach 1:
The battery pack is segmented into standardized, modular units that can be easily added or removed. Each module is designed as a self-contained unit with uniform dimensions and connection interfaces, allowing capacity extension without requiring custom parts or complex modifications, thereby controlling manufacturing costs
3Quantity of substance
If the battery pack is configured with multiple assembled parts, then the capacity can be extended, but structural safety is compromised due to expansion and contraction from repetitive charge and discharge cycles
Solution Approach 1:
The patent incorporates dynamic compensation features in the module assembly structure that allow for expansion and contraction during charge/discharge cycles. The modular design includes flexible connection elements and spacing accommodations that adapt to dimensional changes, maintaining structural safety while enabling capacity extension
Data Source
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AI summary
Disclosed herein is a battery pack including at least one module assembly configured to have a structure in which battery modules, each of which includes a plurality of unit cells electrically connected to each other while being stacked, are arranged while being adjacent to each other, a pair of side support members configured to have a structure to surround sides of the outermost ones of the battery modules of the module assembly, two or more coupling members to couple the side support members to the module assembly, a base plate provided at one surface with fastening parts coupled to the side support members and at the other surface thereof with an external mounting part mounted to an external structure, and a sheathing cover coupled to the base plate while surrounding the module assembly.