Battery Pack Tray Structure for Cell Swelling Control
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Solution Overview
Problem
Conventional battery packs suffer from reduced energy density and increased weight due to separate housing structures, necessitating a design that enhances energy density and reduces weight while efficiently controlling cell swelling.
Innovation Solution
A battery pack design featuring a pack tray with integrated side plates that support battery cell assemblies, omitting additional case structures, and utilizing fastening and connection members to secure the modules, along with an integrated heat sink for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate housing structure is used to accommodate battery cell assemblies, then the battery pack structure is complete and protective, but the energy density is reduced and total weight is increased
Solution Approach 1:
The housing structure is merged with the pack tray by integrating the side plates directly into the tray structure. The side plates are formed as integral parts of the pack tray through stamping or bending processes, eliminating the need for separate housing components while maintaining structural integrity and protection for battery cell assemblies.
Solution Approach 2:
The pack tray is designed to serve multiple functions simultaneously: it provides structural support, acts as a housing for battery modules, offers mounting surfaces for battery cell assemblies, and enables direct fixation without additional fastening components. This multi-functionality reduces the overall number of parts while maintaining reliability.
2Reliability
If a separate housing structure is used to accommodate battery cell assemblies, then the battery pack structure is complete and protective, but the total weight is increased
Solution Approach 1:
The housing structure is merged with the pack tray by integrating the side plates directly into the tray structure. The side plates are formed as integral parts of the pack tray through stamping or bending processes, eliminating the need for separate housing components while maintaining structural integrity and protection for battery cell assemblies.
Solution Approach 2:
The design discards unnecessary separate housing components and fastening elements by integrating their functions into the pack tray structure. The side plates themselves serve as both structural elements and mounting surfaces, eliminating the need for additional bolts, nuts, or separate housing parts, thereby reducing total weight.
3Reliability
If additional case structures are used to support battery modules, then the modules are well-supported and protected, but the structure becomes bulkier and less efficient
Solution Approach 1:
The support function is merged into the pack tray structure itself. The side plates are formed with support portions that directly contact and support battery cell assemblies, eliminating the need for separate case structures or additional support components.
Solution Approach 2:
The side plates utilize the vertical dimension by extending upward from the pack tray base to provide support surfaces for battery modules. This vertical integration allows support functionality without adding horizontal bulk, maintaining a compact structure.
Data Source
AI summary
Discussed is a battery pack provided in a vehicle, the battery pack including a pack tray mounted on the vehicle; and at least one battery module provided on the pack tray, wherein the at least one battery module includes: at least one battery cell assembly mounted on the pack tray, and including at least one battery cell; and a plurality of side plates provided on opposite side surfaces of the at least one battery cell assembly to support the at least one battery cell assembly, the plurality of side plates being fixed to the pack tray, and wherein each of the plurality of side plates includes: a support portion supporting the at least one battery cell assembly; and a fixed portion extending from the support portion, and fixed to the pack tray.