Battery Pack Module Layout for Cell Swelling Pressure Absorption
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Solution Overview
Problem
Conventional battery packs face issues with excessive warpage of frame members and degradation of battery cell life due to the swelling phenomenon during charging and discharging, which conventional compression pads fail to adequately absorb.
Innovation Solution
A battery pack design featuring a first sub-battery module fixed to a pack frame with a pair of second sub-battery modules moving along connection portions, utilizing frame members made of GFRP or CFRP that stretch and absorb pressure deviations, and end plates for stable fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a battery pack is designed to fit within a specific volume, then the device can achieve compact size and portability, but the battery capacity and energy storage are limited
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing one or more battery cells. This segmentation allows flexible arrangement of modules to optimize both space utilization and total capacity, resolving the contradiction between compact volume and sufficient battery capacity.
Solution Approach 2:
The battery modules are arranged in a three-dimensional configuration with specific spacing and positioning. By utilizing vertical and horizontal dimensions efficiently, the design maximizes energy density within the constrained volume while maintaining accessibility for thermal management and electrical connections.
2Volume of moving object
If battery modules are arranged closely to maximize space utilization, then the device achieves compact size, but heat dissipation becomes difficult and thermal management is compromised
Solution Approach 1:
Different regions of the battery pack are designed with different thermal management characteristics. Heat dissipation channels and cooling structures are strategically positioned in high-heat-generation areas, while insulation is provided in low-heat areas. This localized approach enables effective heat management within compact dimensions.
Solution Approach 2:
Thermal management components such as heat sinks, cooling plates, and air channels are introduced as intermediary structures between battery modules. These intermediaries facilitate heat transfer from the battery cells to the external environment without significantly increasing the overall pack volume, resolving the conflict between compact size and heat dissipation.
3Ease of manufacture
If the battery pack structure is simplified to reduce manufacturing complexity, then production cost decreases, but protection against foreign object insertion and electrical safety are compromised
Solution Approach 1:
Multiple functions are merged into single structural elements. The insulating structure simultaneously provides electrical isolation, mechanical support, and foreign object protection. The battery module design integrates structural framing with safety features, reducing the number of separate components while maintaining comprehensive protection against foreign object insertion and electrical hazards.
Solution Approach 2:
The insulating structure and module housing are designed to perform multiple functions: mechanical support, electrical insulation, thermal management integration, and foreign object protection. This multi-functionality reduces overall structural complexity and component count while maintaining safety requirements, making the design easier to manufacture without compromising reliability.
Data Source
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AI summary
A battery pack according to one embodiment of the present disclosure includes a battery module including a first sub-battery module and a pair of second sub-battery modules disposed on both sides of the first sub-battery module, respectively; a pack frame on which the battery module is mounted; and a pair of connection portions that penetrate through the upper and lower portions of the first sub-battery module and the pair of second sub-battery modules, respectively, wherein both sides of the pair of connection portions are fixed to the side surface portion of the pack frame, wherein the first sub-battery module is fixed to the bottom surface of the pack frame, and wherein the second sub-battery module moves along the longitudinal direction of the connection portion.