Battery Pack Tray Bar Structure for Impact Absorption and Energy Density
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Solution Overview
Problem
Conventional battery packs face challenges in securing rigidity and improving energy density due to the use of separate crush beams, which occupy space and reduce efficiency.
Innovation Solution
A battery pack design featuring a pack tray with tray bars and tolerance compensation members that allow battery modules to be closely arranged without separate crush beams, enhancing rigidity and energy density by using tray bars and tolerance compensation members to absorb impacts and compensate for mounting tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate crush beams are provided between battery modules for impact absorption, then reliability is improved, but energy density deteriorates due to gap space
Solution Approach 1:
The patent merges the crush beam function with the battery module structure itself by providing protruding parts on the battery modules that directly contact each other for impact absorption, eliminating the need for separate crush beams and the associated gap spaces, thereby improving energy density while maintaining reliability
Solution Approach 2:
The battery module housing is designed to serve multiple functions: it contains the battery cells and simultaneously provides impact absorption through its protruding parts that act as integrated crush elements, eliminating the need for dedicated crush beams and reducing overall space requirements
2Reliability
If separate crush beams are provided for impact absorption, then reliability is improved, but device complexity increases
Solution Approach 1:
The crush beam function is merged into the battery module housing structure, eliminating separate components and simplifying the overall assembly. The protruding parts on adjacent battery modules directly engage with each other to provide impact absorption without requiring additional structural elements
Solution Approach 2:
The separate crush beam component is extracted from the system and its function is integrated into the battery module housing itself, reducing the number of parts and simplifying the structural complexity while maintaining the impact absorption capability
3Ease of manufacture
If gap space is provided between battery modules and crush beams for mounting tolerance, then ease of manufacture is improved, but energy density deteriorates
Solution Approach 1:
The mounting structure incorporates tolerance compensation members that can dynamically adjust to accommodate dimensional variations in battery modules, allowing for tight spacing without requiring fixed gap spaces, thereby improving energy density while maintaining ease of assembly through the compliant tolerance compensation mechanism
Data Source
AI summary
Discussed is a battery pack including: a battery module assembly including a plurality of battery modules including a plurality of battery cells; a pack tray on which the battery module assembly is accommodated; and a tray bar arranged on at least one side edge of the pack tray.