Battery Pack Separation Wall Coupling Without Welding Beads
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Solution Overview
Problem
Conventional battery packs face issues with inefficient use of internal space due to welding beads interfering with cell assembly seating, leading to improper support and potential weight increase when expanding the internal space to resolve this issue.
Innovation Solution
A battery pack design featuring a base plate that supports cell assemblies, with a separation wall interposed between them, coupled to the base plate using a coupling member that penetrates through the base plate and separation wall, incorporating thread grooves and cooling passages for improved stability and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to couple the separation wall to the base plate, then the separation wall is securely fixed, but welding beads are generated that interfere with cell assembly seating
Solution Approach 1:
The harmful welding beads are extracted/removed from the system by replacing the welding process with a screw coupling mechanism. The separation wall is coupled to the base plate using screws that pass through coupling holes, eliminating the generation of welding beads that interfere with cell assembly seating while maintaining secure fixation
Solution Approach 2:
The welding process (thermal-chemical joining) is replaced with a mechanical screw coupling system. The screw engages with thread grooves in the separation wall and passes through coupling holes in the base plate, providing secure mechanical fixation without generating harmful byproducts
2Object-affected harmful factors
If the internal space of the pack case is expanded to avoid welding bead interference, then cell assembly seating is improved, but the weight of the battery pack increases
Solution Approach 1:
Instead of expanding the internal space to accommodate welding beads, the harmful welding beads are extracted from the system by eliminating the welding process. The screw coupling method fixes the separation wall without generating any interfering elements, maintaining the original compact internal space and avoiding weight increase
3Object-affected harmful factors
If the internal space is expanded to resolve welding bead interference, then seating space is improved, but the separation wall cannot appropriately support the cell assembly
Solution Approach 1:
The welding process is replaced with a mechanical screw coupling system that provides reliable support. The screw engages with thread grooves in the separation wall and is secured through coupling holes in the base plate, creating a strong mechanical connection that appropriately supports the cell assembly without requiring space expansion
Data Source
AI summary
A battery pack including a plurality of cell assemblies, and a pack case providing a space in which the cell assemblies are seated, the pack case including: a base plate supporting a lower portion of the cell assemblies; and a separation wall interposed between a pair of neighboring cell assemblies such that each cell assembly is separated, and coupled to the base plate. The separation wall is coupled to the base plate by a coupling member vertically penetrating the bottom of the base plate.