Long-Cell Battery Pack Structure Without Cross Beams
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Solution Overview
Problem
Existing battery packs in electric vehicles suffer from low space utilization and energy density, leading to reduced capacity, increased weight, and complex assembly processes, which hinder their development.
Innovation Solution
A battery pack design that utilizes long cells with a supporting region connected to a support member, eliminating the need for transverse and longitudinal beams, allowing for improved space utilization and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules are fixed on transverse beams and longitudinal beams by screws, then the battery pack structure is stable, but space is wasted and weight increases
Solution Approach 1:
The patent removes the transverse beams and longitudinal beams from the battery pack structure, extracting the supporting function to the battery module housing itself. The housing is designed with integrated support features that directly engage with the battery pack casing, eliminating the need for separate beam structures and reducing overall weight.
Solution Approach 2:
The patent merges the support function into the battery module housing design. The housing incorporates integrated support plates and positioning features that combine the previously separate functions of beams and module housing, creating a unified structure that reduces component count and weight.
2Strength
If battery modules are fixed on transverse beams and longitudinal beams by screws, then the battery pack structure is stable, but the assembly process becomes complex
Solution Approach 1:
The patent removes the complex beam structure and associated screw-fastening system, extracting only the essential support and positioning functions. This simplifies the assembly process by reducing the number of components and assembly steps required.
Solution Approach 2:
The patent combines multiple functions (support, positioning, and structural integrity) into the integrated housing design, eliminating the need for separate beams and multiple fastening operations, thereby simplifying the assembly process.
3Reliability
If end plates and side plates with certain thickness and height are designed for battery modules, then the cell array is properly contained and supported, but space inside the battery pack is wasted
Solution Approach 1:
The patent employs thin-walled but structurally optimized housing designs for battery modules. The housing walls are designed with sufficient strength for containment while minimizing thickness to maximize internal space. Integrated support plates provide structural reinforcement without requiring thick walls throughout.
Solution Approach 2:
The patent optimizes the dimensional parameters of the housing walls and support structures. By carefully selecting wall thickness and support plate dimensions, the design achieves adequate mechanical strength and containment while minimizing the volume occupied by structural elements, thereby maximizing space utilization.
4Reliability
If a complicated assembly process with multiple procedures is used, then the battery pack can be properly assembled, but labor and material costs increase and defect rate increases
Solution Approach 1:
The patent removes unnecessary assembly steps and intermediate components (beams, multiple fastening operations), extracting only the essential assembly actions required to achieve proper positioning and structural integrity. This reduces assembly complexity while maintaining quality.
Solution Approach 2:
The patent combines multiple assembly operations into fewer integrated steps. The modular housing design with integrated support features allows for direct installation without intermediate beam attachment steps, reducing the number of procedures and associated costs while maintaining assembly quality through design-driven precision.
Data Source
AI summary
A battery pack, a vehicle, and an energy storage device are provided. The battery pack includes a cell array and a support member, where the cell array includes a plurality of cells, the cell has a first dimension, and the first dimension is a maximum spacing between two imaginary parallel planes sandwiching the cell; and at least one of the cells 600 mm≤first dimension≤2500 mm the at least one cell includes a casing and a core located inside the casing, a supporting region is formed on the casing, and the cell is connected to the support member through the supporting region and is supported by the support member. The support member is connected to the supporting region to support the cell.