Battery Pack Side Support Layout for Dense Module Assembly
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Solution Overview
Problem
Existing battery packs for vehicles are large, heavy, and costly, with inefficient assembly processes that hinder compact and cost-effective configurations.
Innovation Solution
A battery pack design featuring offset side walls and releasable side support members that allow for compact stacking and easy assembly, utilizing mechanical fasteners and support sections for secure attachment, enabling efficient use of space and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional battery pack designs are used, then structural strength is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The battery pack is divided into modular battery modules that can be independently assembled and positioned within the housing. Each module contains a stack of battery cells with integrated support structures, allowing the system to achieve required strength through modular assembly rather than complex monolithic construction
Solution Approach 2:
The side support members are merged with the housing structure through releasable attachment mechanisms, combining the functions of structural support and housing integration into single components. This reduces the number of separate parts while maintaining structural integrity
2Quantity of substance
If battery modules are densely packed, then energy density increases, but assembly difficulty increases
Solution Approach 1:
The side support members feature releasable attachment mechanisms that allow them to be temporarily detached during assembly to accommodate battery module insertion, then reattached to secure the modules in place. This dynamic assembly approach enables dense packing while maintaining manufacturing ease
Solution Approach 2:
Battery modules are arranged in a stacked configuration along the longitudinal axis of the housing, utilizing vertical space efficiently. The offset side walls create a tapered configuration that optimizes space utilization in the longitudinal dimension while facilitating module insertion from the end of the housing
3Volume of moving object
If offset side walls are used, then space utilization improves, but manufacturing precision requirements increase
Solution Approach 1:
The offset side walls are implemented as separate, detachable components rather than integral parts of the housing. This segmentation allows each side wall to be manufactured independently with standard precision, then assembled in the offset configuration using the releasable attachment mechanisms, eliminating the need for high-precision monolithic manufacturing
Data Source
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AI summary
The disclosure relates to a battery pack (1), the battery pack (1) having a longitudinal extension in a longitudinal direction (L), a width extension in a width direction (W), and a height extension in a height direction (H), the battery pack (1) comprising: - a plurality of battery modules (20, 22, 24), wherein each battery module (20, 22, 24) comprises a plurality of battery cells (202), - a housing (30), wherein the housing (30) comprises a first side wall (32) and a second side wall (34) having a respective extension in the longitudinal direction (L) and the height direction (H), and - at least one first pair of side support members (40, 42; 40', 42'; 40") for carrying at least one of the battery modules (20, 22, 24) in the housing (30). The disclosure also relates to a method and to a vehicle.