Battery Pack Tray Support Structure for Impact and Pressure Relief
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Solution Overview
Problem
Battery packs face poor impact protection and safety issues due to inadequate protection of the battery module's bottom and rapid pressure relief, which can lead to open fires during thermal runaway.
Innovation Solution
The battery pack design includes a case body with an accommodation trough and pressure relief members, featuring trays with supports that form a pressure relief cavity, where the supports have through holes for adhesive bonding and provide additional rigidity and obstruction to high-temperature substances, enhancing impact resistance and safety by slowing down the discharge of high-temperature gases and reducing oxygen levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery module is protected only by the bottom plate, then the structure is simple, but the impact protection effect is poor
Solution Approach 1:
The bottom protection structure is segmented into multiple components: the bottom plate, multiple supports distributed beneath the tray, and the tray itself. This segmentation distributes the impact force across multiple elements rather than relying on a single bottom plate, significantly improving impact protection while maintaining reasonable structural complexity.
Solution Approach 2:
The protection system uses a composite structure combining the bottom plate material, support materials, and tray materials. Each component can be optimized for specific properties (rigidity, shock absorption, strength), creating a composite protection system that outperforms a single bottom plate structure.
2Reliability
If pressure relief is performed quickly through the pressure relief member, then the pressure relief speed is high, but the oxygen inside the pressure relief cavity is not exhausted and open fire occurs
Solution Approach 1:
Before the high-pressure gas is discharged, the supports are pre-positioned to obstruct the pressure relief cavity. This preliminary arrangement ensures that when pressure relief occurs, the oxygen has already been slowed down and partially exhausted, preventing open fire even though the pressure relief speed remains relatively high.
Solution Approach 2:
The supports act as an intermediary element between the pressure relief member and the external environment. They mediate the pressure relief process by obstructing and slowing the high-pressure gas flow, allowing oxygen to be exhausted while still maintaining adequate pressure relief speed. This intermediary structure prevents direct rapid discharge that would cause open fire.
3Reliability
If the supports are added to form a pressure relief cavity with obstruction, then the safety is improved by slowing down high-temperature substances, but the device complexity increases
Solution Approach 1:
The supports serve multiple functions simultaneously: they provide impact protection by distributing mechanical loads, they obstruct the pressure relief cavity to slow down high-temperature substances and exhaust oxygen, and they maintain structural integrity of the battery pack. This multi-functionality improves safety without proportionally increasing complexity, as a single component structure achieves multiple protection goals.
Data Source
AI summary
A battery pack includes: a case body including an accommodation trough and a pressure relief member; battery modules; and trays each corresponding to corresponding one of the battery modules and including a tray body and supports; where each of the battery modules is bonded to an upper side of the tray body by an adhesive, a first end of each of the supports is connected to the tray body, a second end of the support is in contact with a bottom portion of the accommodation trough, the tray body and the bottom portion of the accommodation trough are spaced apart to form a pressure relief cavity communicating with the pressure relief member, each of the supports is provided with a first through hole, and the adhesive is bonded to the bottom portion of the accommodation trough through the first through hole from the upper side.