Stackable Battery Module Side Walls for Stable Frame-Free Stacking
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Solution Overview
Problem
Existing battery stacks for vehicles face challenges in providing a flexible and stable structure for vertically stacked battery modules, which often require additional internal frames for support, increasing complexity and cost.
Innovation Solution
A battery stack design featuring integrated stackable support structures with opposing side walls and stacking members that lock modules in place, providing stability without the need for additional frames, allowing for efficient vertical stacking of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If additional internal frames or shelves are added for module support, then mechanical stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the support function into the side walls themselves by integrating stacking members directly onto the side wall structures. The side walls are designed with protrusions and recessions that provide stacking functionality without requiring separate internal frames or shelves, thus combining structural support and stacking functions into a single integrated component.
Solution Approach 2:
The side walls serve multiple functions: they provide structural support for the battery modules, act as stacking members for vertical assembly, and eliminate the need for separate support frames. This multi-functional design reduces overall device complexity while maintaining mechanical stability.
2Stability of the object's composition
If additional internal frames or shelves are added for module support, then mechanical stability is improved, but manufacturing cost increases
Solution Approach 1:
By combining the support function into the side walls through integrated stacking members, the patent eliminates the need for separate support frames or shelves. This reduction in component count directly lowers manufacturing costs while maintaining the required mechanical stability for withstanding vehicle vibrations and loads.
3Volume of moving object
If battery modules are vertically stacked in several layers, then space utilization is improved, but mechanical durability under vibration and load decreases
Solution Approach 1:
The patent segments the stacking function into discrete stacking members with protrusions and recessions that create localized connection points between modules. This segmentation allows each module to be independently supported at specific locations, distributing mechanical stresses and improving overall durability under vibration and load conditions while maintaining compact vertical stacking.
4Device complexity
If integrated stackable support structures are used, then device complexity is reduced, but stacking stability may be compromised
Solution Approach 1:
The stacking members feature asymmetric protrusions and recessions designed to mate with each other in a specific orientation. This asymmetric design provides stable stacking while maintaining simplicity, as the protrusion-recession geometry inherently guides proper assembly and prevents misalignment without requiring complex additional components.
Data Source
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AI summary
The present invention relates to a battery stack 1 for a vehicle 2, the battery stack 1 comprising a first battery module 4 and a second battery module 5, each comprising battery cells 6,7 being stacked in a depth direction z. The first battery module 4 and the second battery modules 5 each comprises a first and a second supporting side wall 8,9,10,11 for supporting the battery cells 6,7 in the respective first and second battery module 4,5. The first and the second supporting side walls 8,9,10,11 are provided on a respective side of the battery cells 6,7 of the respective battery modules 4,5 and extend in a height direction y between a respective upper edge surface 8a,9a,10a,11a and a respective lower edge surface 8b,9b,10b,11b of the respective side walls 8,9,10,11. The respective upper edge surface 8a,9a of the first and the second side walls 8,9 of the first battery module 4 are provided with a respective upper stacking member 12,13 and the respective lower edge surface 10b,11b of the first and the second side walls 10,11 of the second battery module 5 are provided with a respective lower stacking member 14,15. The lower stacking members 14,15 of the second battery module 5 being configured to fit on and being supported by the upper stacking members 12,13 of the first battery module 4 when stacking the second battery module 5 onto the first battery module 4 in the height direction y.