Plastic Cell Tray Reinforcement for Lightweight Battery Modules

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Solution Overview

Problem

Current battery trays are heavy, lack toughness, and have poor insulation performance, necessitating additional insulating materials, which complicates their design and increases weight.

Innovation Solution

A cell tray made of fully plastic materials with integrated reinforcement parts and cell positioning members, enhancing support strength and toughness while maintaining lightweight properties, and incorporating features for pressure relief and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal sheets are used to manufacture battery trays, then support strength is improved, but weight increases and toughness deteriorates

Engineering Contradiction:

Improvesupport strengthVSAvoidtray weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material parameter from metal to plastic, fundamentally altering the weight and toughness characteristics while maintaining structural functionality through design optimization

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs plastic composite materials that combine lightweight properties with enhanced mechanical strength, achieving a balance between weight reduction and support strength requirements

Inventive Principle:

Principle #40Composite materials

2Strength

If metal sheets are used to manufacture battery trays, then support strength is improved, but insulation performance deteriorates

Engineering Contradiction:

Improvesupport strengthVSAvoidinsulation performance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from conductive metal to insulating plastic, simultaneously achieving electrical insulation while maintaining mechanical strength through structural design

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The plastic material provides homogeneous insulation properties throughout the entire tray structure, eliminating the need for additional insulating layers required with metal trays

Inventive Principle:

Principle #33Homogeneity

3Object-affected harmful factors

If additional insulating films or spray-coated insulating layers are added to metal trays, then insulation performance is improved, but device complexity increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidtray structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the insulation function directly into the tray material itself, eliminating the need for separate insulating films or spray-coated layers, thereby simplifying the overall structure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic tray material simultaneously provides structural support, electrical insulation, and toughness, making the tray component multi-functional and reducing the need for additional specialized layers

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20260038952A1Cell tray, battery module, and battery pack

Publication Date: 2026.02.05 EVE ENERGY CO LTD

AI summary

A cell tray, a battery module, and a battery pack are provided. The battery pack includes the battery module. The battery module includes cells and a cell tray. The cell tray includes a tray body and a reinforcement part provided on the tray body. The tray body is provided with a plurality of cell positioning members to fix positions of the cells. The reinforcement part is disposed in an offset manner with the plurality of cell positioning members. The tray body and the reinforcement part are both made of fully plastic materials.