Stackable Battery Module Side Walls for Stable Vertical Stacking
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Solution Overview
Problem
Existing battery stacks for vehicles face challenges in efficiently utilizing limited space while maintaining mechanical durability and reducing complexity and cost, particularly in trucks and commercial vehicles where multiple battery modules are stacked, often requiring additional internal frames for support.
Innovation Solution
A battery stack design featuring stackable modules with integrated supporting side walls and stacking members that allow modules to be securely stacked in the height direction, using upper and lower stacking members that fit together, and optionally include flanges for additional support, reducing the need for internal frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal frame/shelves are added for module support, then mechanical durability is improved, but device complexity and cost increase
Solution Approach 1:
The patent integrates the support function directly into the side walls of adjacent battery modules. The side walls are designed with protruding portions that extend into the void space between modules, providing structural support without requiring separate internal frames or shelves. This merging of support functionality into existing structural components reduces overall device complexity while maintaining mechanical durability.
2Volume of moving object
If multiple battery modules are stacked vertically, then space utilization is improved, but mechanical stability under vibration and load deteriorates
Solution Approach 1:
The side walls are designed with localized protruding portions at specific heights that engage with corresponding features on adjacent modules. This local structural modification provides targeted support at critical points where vibration and load forces are most impactful, enhancing overall stack stability without requiring comprehensive reinforcement of entire structures.
Solution Approach 2:
The patent utilizes the depth dimension by extending protruding portions from side walls into the void space between modules. This three-dimensional engagement creates interlocking geometry that resists vertical separation and lateral shifting, improving mechanical stability in the stacked configuration while maintaining compact space utilization.
3Reliability
If internal frame/shelves are added for module support, then mechanical durability is improved, but manufacturing cost increases
Solution Approach 1:
The support structure is merged with the side wall components of battery modules, eliminating the need for separate internal frames or shelves. This reduces the total component count and simplifies manufacturing processes, as the support function is integrated into existing structural elements rather than requiring additional parts and assembly steps.
Data Source
AI summary
A battery stack includes a first battery module and a second battery module, each comprising battery cells being stacked in a depth direction. The first battery module and the second battery modules each comprises a first and a second supporting side wall supporting the battery cells. The first and the second supporting side walls are on a respective side of the battery cells of the respective battery modules and extend in a height direction between a respective upper edge surface and a respective lower edge surface of the respective side walls. The respective upper edge surface of the first and the second side walls of the first battery module have a respective upper stacking member and the respective lower edge surface of the first and the second side walls of the second battery module have a respective lower stacking member. The lower stacking members of the second battery module fit on and are supported by the upper stacking members of the first battery module when stacking the second battery module onto the first battery module in the height direction.