Battery Module Support Member Layout for Dense Pack Assembly
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Solution Overview
Problem
Conventional battery packs face challenges in maintaining high energy density and structural rigidity due to manufacturing tolerances, which lead to increased dead space and limitations in accommodating large battery modules, especially in electric vehicles where high power and spatial constraints are critical.
Innovation Solution
The introduction of a battery module design that includes a support member between battery cells, with an extension portion protruding beyond the end covers, which is coupled to the pack housing, providing structural stability and allowing for efficient packing of multiple modules within a limited space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If more battery modules are disposed to increase output, then power output is improved, but dead space increases and energy density is lowered
Solution Approach 1:
The support member is integrated within the module housing structure, with its extension portion nested between the end covers. This nested configuration allows the support member to provide structural reinforcement without occupying additional external space, thereby reducing dead space while supporting higher power output requirements through proper module arrangement.
Solution Approach 2:
The support member extends in the second direction (perpendicular to battery cell stacking) beyond the end covers, utilizing the lateral dimension rather than adding length in the stacking direction. This dimensional approach allows structural support without increasing the footprint that would create dead space, enabling better space utilization for higher energy density.
2Strength
If frame structure is added for structural rigidity, then structural stability is improved, but dead space increases and accommodates large battery modules
Solution Approach 1:
The support member is merged with the module housing structure, forming an integrated assembly where the support member's extension portion becomes part of the overall module structure. This combination eliminates the need for separate frame structures within the battery pack, as the support members collectively provide the necessary rigidity without creating additional dead space.
Solution Approach 2:
The support member serves multiple functions: it provides structural rigidity to the module, acts as a positioning element between battery cells, and its extension portion between end covers serves as a coupling interface with the pack housing. This multi-functionality replaces the need for dedicated frame structures, maximizing space for battery modules.
3Stability of the object's composition
If support member extends beyond end covers, then structural stability is improved and coupling to pack housing is enabled, but device complexity increases
Solution Approach 1:
The support member is segmented into two functional portions: a body portion that provides internal structural support between battery cells, and an extension portion that protrudes between end covers for external coupling. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural stability without excessive complexity.
Data Source
AI summary
Provided is a battery module, the battery module including: a plurality of battery cells stacked in a first direction; a support member disposed between the plurality of battery cells; a module housing in which the plurality of battery cells are accommodated; and a plurality of end covers coupled to the module housing, and facing the plurality of battery cells in a second direction, perpendicular to the first direction, wherein the support member protrudes further in the second direction from the plurality of end covers.