Electric Vehicle Battery Pack External Frame Stiffness
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Solution Overview
Problem
The battery pack for electric vehicles requires sufficient stiffness to withstand the weight of the batteries while maintaining insulation, but increasing stiffness leads to a larger space requirement, which is not feasible without increasing the thickness of the battery container.
Innovation Solution
A battery pack design featuring a battery container made of insulating resin with an external frame unit that includes a lower support section, an upper support section, and a coupling section, allowing the battery container to be lifted and supported without excessive stiffness, thus preventing thickness increase, and ensuring insulation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the battery container is increased to increase stiffness, then the stiffness is improved, but the space inside the electric vehicle required to mount the battery container increases
Solution Approach 1:
The support function is segmented from the battery container to an external frame unit. The battery container focuses on insulation and battery accommodation, while the external frame unit provides structural support and lifting capability. This segmentation allows the battery container to remain thin without compromising overall stiffness.
Solution Approach 2:
The external frame unit acts as an intermediary between the battery container and the lifting/mounting operations. It provides the necessary mechanical strength and support without requiring the battery container itself to be thick, thus resolving the contradiction between container thickness and stiffness.
2Strength
If the thickness of the battery container is increased to provide sufficient stiffness for lifting, then the stiffness is improved, but the insulation property and space efficiency deteriorate
Solution Approach 1:
The functions of support, lifting, and insulation are separated into different components. The external frame unit handles support and lifting, while the thin battery container maintains insulation. This functional segmentation optimizes space efficiency while ensuring adequate stiffness for lifting operations.
3Volume of moving object
If the battery container is made thinner to reduce space requirements, then the space efficiency is improved, but the stiffness deteriorates
Solution Approach 1:
The external frame unit serves as a mediator that provides the necessary stiffness and support structure without requiring the battery container to be thick. This allows the container to be optimized for space efficiency while the frame unit ensures adequate mechanical strength for lifting and mounting.
4Volume of moving object
If the battery container is made thinner to improve space utilization, then the space utilization is improved, but the ability to withstand battery weight deteriorates
Solution Approach 1:
The load-bearing function is segmented from the battery container to the external frame unit. The container focuses on space-efficient battery accommodation, while the frame unit provides the structural strength to withstand battery weight during lifting and mounting operations.
Solution Approach 2:
The external frame unit acts as an intermediary structure that bears the battery weight and provides lifting capability, allowing the battery container to be thin and space-efficient without compromising the ability to withstand battery weight.
Data Source
AI summary
A battery pack comprises a plurality of batteries which store electric power for activating an electric utility vehicle; a battery case which accommodates the plurality of batteries therein; and an external frame unit which is provided on an outer surface of the battery case and supports the batteries from below, wherein the external frame unit includes a lower support section placed on a lower surface of the battery case, an upper support section placed on an upper surface of the battery case, and a coupling section which couples the lower support section and the upper support section to each other. This allows the battery case to ensure a required stiffness while providing insulation between the batteries and an outside of the batteries, without increasing a thickness of the battery case.