Segmented ESS Battery Pack Case for Component Accommodation
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Solution Overview
Problem
Conventional energy storage system (ESS) battery pack cases face challenges in accommodating additional electric components like DC-DC converters due to space restrictions and fail flame spread resistance tests due to pressure deformation during ignition.
Innovation Solution
The ESS battery pack case design features a case body assembled from multiple plates via extrusion molding, allowing for expansion in the lateral direction, with a drainage hole and anti-swelling structure, and includes a double cover assembly with metal strength-reinforcing plates to prevent deformation and facilitate pressure discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the case body is integrally manufactured by extrusion molding, then manufacturing simplicity is improved, but the width in lateral direction cannot be widened and space for additional components is restricted
Solution Approach 1:
The case body is divided into multiple unit plates (first unit plate, second unit plate, third unit plate, fourth unit plate) that are assembled together through fitting. This segmentation allows the case body to achieve a larger width in the lateral direction while maintaining manufacturing simplicity, as each unit plate can be manufactured separately and then connected to form the complete structure.
2Ease of manufacture
If the case body is integrally manufactured by extrusion molding, then manufacturing simplicity is improved, but pressure discharge capability deteriorates during flame spread resistance test
Solution Approach 1:
The case body is segmented into multiple unit plates connected by fitting, which creates natural separation planes. During a flame spread resistance test, this segmented structure allows pressure to be discharged more effectively through the joints between plates, preventing the case body from deforming or exploding as would occur with an integrally molded structure.
Solution Approach 2:
The fitting connections between unit plates act as intermediaries that facilitate pressure discharge. These joints provide pathways for pressure relief during thermal events, serving as a mediator between the internal pressure buildup and the external environment, thereby improving flame spread resistance while maintaining manufacturing simplicity.
3Adaptability or versatility
If additional electric components are incorporated, then functionality is improved, but space requirements increase which conflicts with conventional case design
Solution Approach 1:
By dividing the case body into multiple unit plates that can be assembled in various configurations, the design provides flexible internal space that can accommodate additional electric components such as DC-DC converters without significantly increasing the overall case size. The segmented structure allows for optimized component placement within the available volume.
Data Source
AI summary
Disclosed is an energy storage system (ESS) battery pack case, which includes a case body having at least two plates assembled to each other by fitting so as to be connected to each other along a circumferential direction thereof to form a hollow therein, the case body having an open top end and an open bottom end; and an upper cover assembly configured to cover the top end of the case body and a lower cover assembly configured to cover the bottom end of the case body.