Battery Pack Sliding Module Coupling for Load Distribution
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Solution Overview
Problem
Conventional battery packs suffer from reduced space utilization and structural instability due to empty spaces between modules and concentrated load on bolt coupling points, which also complicates the assembly process.
Innovation Solution
The battery pack design incorporates sliding guide rails and protrusions on both the modules and tray, allowing for surface contact and sliding coupling, along with module support beams to distribute load and prevent empty spaces, enhancing assembly efficiency and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules are spaced apart and coupled by bolting using long bolts, then the coupling strength between modules and tray is improved, but the space utilization of the battery pack is reduced and the load is concentrated on the bolt coupling portion
Solution Approach 1:
The coupling structure is segmented into multiple coupling points distributed across the battery module surfaces, rather than relying on a few long bolts. The side surfaces are divided into multiple coupling regions that can independently engage with the tray, distributing the mechanical interaction across multiple locations.
Solution Approach 2:
The coupling mechanism transitions from vertical bolting (single dimension) to multi-directional surface contact. The battery modules make surface contact with the tray in multiple dimensions through their side surfaces, creating a distributed coupling system that eliminates empty spaces while maintaining strength.
2Reliability
If battery modules are spaced apart and coupled by bolting, then the modules are securely fixed to the tray, but the structural stability is deteriorated due to concentrated load on bolts
Solution Approach 1:
The load-bearing structure is segmented into multiple coupling points on the side surfaces of battery modules. Each segment independently contributes to load distribution, preventing concentration of stress on single bolt locations and enhancing overall structural stability.
Solution Approach 2:
Different regions of the battery module side surfaces are designed with specific coupling characteristics. The local coupling areas have optimized contact surfaces and geometric features that enhance load distribution and structural stability at each specific location while maintaining overall system reliability.
3Strength
If long bolts are used to couple battery modules to the tray, then the coupling strength is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The complex bolting operation is extracted and replaced by simpler surface contact coupling mechanisms. The side surface coupling structures are designed to engage directly with the tray without requiring separate fastening operations, eliminating the need for long bolts and associated assembly complexity.
Solution Approach 2:
The battery module coupling structures are designed to self-align and self-couple with the tray through their geometric features. The side surfaces with specific profiles automatically engage with corresponding tray features during placement, eliminating the need for manual bolt installation and simplifying the assembly process.
Data Source
AI summary
Disclosed is a battery pack, which includes a plurality of battery modules, each having at least one battery cell, and a battery tray to which the plurality of battery modules are mounted. The plurality of battery modules are coupled to each other by sliding and make surface contact with each other on at least one side surface thereof.