Slit End Plate Battery Pack Frame for Welded Sealing Stability
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Solution Overview
Problem
The assembly of battery pack frames is hindered by differences in length between the U frame and the top frame, leading to incomplete sealing and instability in coupling, which can result in foreign matter infiltration and electrical connection issues, especially in vehicles subjected to external forces.
Innovation Solution
Incorporating slits in the end plates that can be deformed to match the length of the battery pack frame and top frame, allowing for close contact through welding, and using a pressing jig with varying pressing forces to ensure proper alignment and coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the U frame and top frame are coupled with different lengths, then the battery pack can accommodate varying frame dimensions, but the sealing and coupling stability deteriorate due to gaps between the end frame and top frame
Solution Approach 1:
The end plate is designed with a deformation section that can dynamically change shape during the coupling process. This deformation section includes a first section coupled to the U frame and a second section that extends toward the top frame, allowing the end plate to adapt its shape to bridge the gap between frames of different lengths and achieve stable sealing contact.
Solution Approach 2:
The end plate's shape is changed through controlled deformation in the deformation section. By changing the geometric parameters of the end plate (specifically the shape of the deformation section), it can accommodate different frame length differences while maintaining reliable sealing contact between the end frame and top frame.
2Strength
If the end frame is closely coupled to the protruded U frame, then the coupling strength improves, but the electrical connection and sealing deteriorate due to gaps between the end frame and top frame
Solution Approach 1:
The deformation section of the end plate acts as an intermediary element between the U frame and the top frame. It extends from the U frame toward the top frame, filling the gap and providing a continuous conductive path that ensures both mechanical coupling strength and stable electrical connection between battery cells.
3Adaptability or versatility
If independent cover members are used to surround the cell assembly, then the structural flexibility improves, but the manufacturing precision and assembly convenience deteriorate due to the need for precise position control during welding
Solution Approach 1:
The end plate integrates multiple functions that were previously separate: it combines the sealing function, the electrical connection function, and the positioning function into a single component. This merging eliminates the need for precise position control of multiple separate cover members during welding, as the deformation section of the end plate automatically adapts to achieve proper alignment and contact.
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
This solution provides stable sealing, prevents foreign substance infiltration, and enhances the reliability of electrical connections by ensuring a secure coupling of the battery pack components, even when frame lengths differ.
Implementation Method 1
at least one of the first end plate and the second end plate is configured to form slits
Implementation Method 2
pressing jig with varying pressing forces to ensure proper alignment and coupling
Implementation Method 3
allowing for close contact through welding
Data Source
AI summary
A battery pack is provided including a battery module having a plurality of battery cells or a unit module having the plurality of battery cells; a battery pack frame body including a base plate on which the battery module or the unit module is mounted, and a first side plate and a second side plate connected to the base plate and disposed to face each other; a top frame coupled to an upper portion of the battery pack frame body; and a first end plate and a second end plate electrically connected to electrode terminals of the battery module or the unit module, wherein at least one of the first end plate and the second end plate is configured to include slits.