Battery Module Band and Side-Plate Structure for Lightweight Packs
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Solution Overview
Problem
Conventional battery packs suffer from reduced energy density and increased weight due to the weight and volume of separate housing structures, necessitating a design that enhances energy density and reduces overall weight.
Innovation Solution
A battery pack design featuring a pack tray with battery modules supported by side plates and covered by band assemblies, eliminating the need for a separate housing case, and incorporating a heatsink for cooling, which stabilizes the modules and enhances structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate box-shaped metallic housing structure is used to accommodate battery cell assemblies, then structural support and protection are provided, but energy density is reduced and overall weight is increased
Solution Approach 1:
The housing structure and mounting functions are merged into an integrated pack tray that serves both structural support and battery module mounting purposes, eliminating the need for separate housing components and reducing overall weight while maintaining structural integrity
Solution Approach 2:
The pack tray is designed as a multi-functional component that provides structural support, accommodates battery modules, and enables mounting to the vehicle body, allowing a single component to fulfill multiple functions previously requiring separate parts
2Strength
If a separate box-shaped metallic housing structure is used to accommodate battery cell assemblies, then structural support and protection are provided, but overall weight is increased
Solution Approach 1:
The housing structure and mounting functions are merged into an integrated pack tray that serves both structural support and battery module mounting purposes, eliminating the need for separate housing components and reducing overall weight while maintaining structural integrity
Solution Approach 2:
The pack tray utilizes thin-walled metallic structures that provide sufficient structural support with minimized material usage, reducing weight while maintaining necessary strength and rigidity for supporting battery modules
3Reliability
If conventional housing structures are used, then battery cells are accommodated, but cell swelling control is insufficient
Solution Approach 1:
The band unit is designed with elastic properties that allow it to dynamically adapt to battery cell swelling during charge-discharge cycles, providing continuous gentle compression that controls swelling without requiring complex mechanical adjustment mechanisms
Solution Approach 2:
The elastic band unit changes its compression force in response to temperature and swelling variations, automatically adjusting its mechanical properties to maintain optimal compression pressure throughout battery operation without external control systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design increases energy density, reduces overall weight, and efficiently controls cell swelling, resulting in a more compact and lightweight battery pack.
Implementation Method 1
a band unit connected to the pair of side plates and configured to at least partially cover an upper side and a lower side of the battery cell assembly
Data Source
AI summary
A battery pack includes a pack tray; and at least one battery module provided on the pack tray. The at least one battery module includes a battery cell assembly mounted on the pack tray and including at least one battery cell; a pair of side plates provided on both side surfaces of the battery cell assembly to support the battery cell assembly and fixed to the pack tray; and a band unit connected to the pair of side plates and configured to at least partially cover an upper side and a lower side of the battery cell assembly.