Integrated Battery Side Frame for Higher Pack Energy Density
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Solution Overview
Problem
The existing battery pack housings in electric vehicles have non-energy-containing components such as end plates, side frames, and sealing flanges that occupy significant space, reducing the energy density of the battery packs.
Innovation Solution
An integrated side frame that combines the functions of a side frame, end plate, and sealing flange, allowing them to be stacked vertically to minimize non-energy-containing space, thereby increasing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate components (end plate, side frame, sealing flange) are used horizontally stacked, then structural integrity and sealing are ensured, but non-energy-storage volume increases reducing energy density
Solution Approach 1:
The patent combines the end plate, side frame, and sealing flange into a single integrated side frame component. This merging eliminates the need for separate horizontal stacking of multiple components, reducing the overall non-energy-storage volume while maintaining the structural integrity and sealing functions through the integrated design.
Solution Approach 2:
The integrated side frame incorporates nested functional elements where the sealing flange and end plate functions are nested within the side frame structure. This nesting arrangement allows multiple functions to be achieved within a compact volume, minimizing the space occupied by non-energy-containing components.
2Reliability
If more separate components are used for housing functions, then sealing and structural support are improved, but energy density decreases due to increased non-energy-containing space
Solution Approach 1:
The patent merges multiple housing functions (sealing, structural support, end plate function) into a single integrated side frame component. This consolidation maintains reliable sealing performance through the integrated sealing flange while eliminating the volume occupied by separate components, thereby increasing energy density.
3Ease of manufacture
If traditional horizontal stacking of housing components is used, then ease of assembly is maintained, but volume efficiency is reduced
Solution Approach 1:
The integrated side frame combines multiple functions into one component that can be assembled as a single unit, maintaining ease of manufacture while significantly reducing the total volume occupied by housing components compared to traditional horizontal stacking of separate parts.
Data Source
AI summary
An energy storage system includes a vehicle and a battery pack disposed within the vehicle. The battery pack includes a number of battery cells and a housing surrounding the battery cells. The housing includes an upper housing cover, a lower housing cover, an end plate, and a side frame coupled to the upper housing cover by an upper sealing flange of the side frame, and coupled to the lower housing cover by a lower sealing flange of the side frame. A majority of the volume of the end plate fits within a recess of the side frame, such that a majority of the volume of the side frame, upper sealing flange, lower sealing flange, and end plate is stacked vertically.