Thin-Plate Battery Module Housing for Rigidity and Space Utilization
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Solution Overview
Problem
Conventional battery modules have limited space utilization and reduced energy density due to thick module housings, which compromise mechanical rigidity and assembly strength when used in battery packs.
Innovation Solution
A battery module with a thin plate-type module housing featuring a base plate, cover plate, and integrated impact-absorbing leaf springs, along with a fastening flange for enhanced rigidity and space efficiency, and a battery pack design with rigid beams and a pack cover for secure mounting and impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick steel plate module housing is used, then mechanical rigidity and protection from external impact are improved, but space utilization and energy density are reduced
Solution Approach 1:
The patent replaces the conventional thick steel plate module housing with a thin-plate type module housing having a thickness of 0.5mm to 2mm. The thin plate housing includes a plate body forming the housing and a reinforcing rib protruding from the plate body to provide mechanical strength. This allows the housing to maintain adequate rigidity while significantly reducing thickness and increasing space utilization for battery cells.
2Object-affected harmful factors
If a thick steel plate module housing is used, then protection from external impact is improved, but weight is increased
Solution Approach 1:
The thin plate housing with reinforcing ribs provides adequate impact protection while significantly reducing weight compared to conventional thick steel plate housings. The reinforcing ribs are strategically positioned to provide structural support and impact resistance without requiring increased overall thickness.
3Reliability
If clearance is provided between battery module and cross beam, then assembly tolerance and strength reliability are secured, but space utilization of pack tray is reduced
Solution Approach 1:
The module housing is segmented into a plate body and reinforcing ribs, allowing optimized distribution of structural functions. The reinforcing ribs provide localized reinforcement at critical areas while maintaining thin overall thickness, enabling reduced clearance requirements in the pack tray assembly.
4Stability of the object's composition
If rigid module housing is used, then structural stability is improved, but welding rate and energy share in pack tray are reduced due to space occupied by housing thickness
Solution Approach 1:
The thin plate housing with reinforcing ribs maintains structural stability through optimized rib positioning and geometry while reducing overall thickness. This reduction in housing thickness directly increases the welding rate and energy share of battery modules in the pack tray by freeing up assembly space.
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 solution allows for increased cell volume ratio, reduced weight, and improved mechanical rigidity in battery modules, enabling efficient space utilization and enhanced protection against mechanical impacts in battery packs.
Implementation Method 1
both side surfaces of the module housing are provided with impact-absorbing leaf springs
Data Source
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AI summary
Disclosed is a battery module having a plurality of battery cells and a module housing forming an inner space for accommodating the battery cells, wherein the module housing includes a base plate forming a bottom surface of the module housing; a cover plate integrally forming a top surface and both side surfaces of the module housing; and a fastening flange configured to extend in a horizontal direction in a region above both side surfaces of the module housing.