Battery Array Vibration Prevention via Grooved Binding Bars

Solution Overview

Problem

Existing battery arrays for automotive applications face challenges in reliably preventing up-and-down vibration of rectangular battery cells, which can lead to insulation breakdown, leakage currents, and physical damage due to excessive pressure from binding bars.

Innovation Solution

The battery array employs plate-shaped binding bars with high bending strength that extend along the battery stack surfaces, linked with separators to prevent up-and-down movement, and L-shaped binding bars with horizontal sections inserted into grooves on the separators to securely hold the stack together, thereby minimizing vibration and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If binding bars are tightened to apply more pressure on the battery stack, then rectangular battery cell vibration is reduced, but separator distortion and rectangular battery cell distortion occur

Engineering Contradiction:

Improvebattery cell vibration preventionVSAvoidseparator integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention changes the binding mechanism from direct pressure application to geometric constraint. By designing the binding bar with a specific shape that fits into the separator groove, the system transitions from force-based vibration prevention to structure-based vibration prevention, eliminating the need for excessive pressure that causes distortion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The groove structure acts as an intermediary element between the binding bar and the separator. Instead of the binding bar directly pressing on the separator (which causes distortion), the groove mediates the interaction by providing a geometric constraint that prevents up-and-down movement without applying damaging pressure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If binding bars are loosened to reduce pressure on the battery stack, then separator distortion is avoided, but rectangular battery cell vibration increases

Engineering Contradiction:

Improveseparator integrityVSAvoidbattery cell vibration prevention

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention changes the binding mechanism from direct pressure application to geometric constraint. By designing the binding bar with a specific shape that fits into the separator groove, the system transitions from force-based vibration prevention to structure-based vibration prevention, eliminating the need for excessive pressure that causes distortion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The groove structure acts as an intermediary element between the binding bar and the separator. Instead of the binding bar directly pressing on the separator (which causes distortion), the groove mediates the interaction by providing a geometric constraint that prevents up-and-down movement without applying damaging pressure

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If angled binding bars are used to retain battery cells, then battery cells are held in position, but up-and-down vibration cannot be reliably prevented

Engineering Contradiction:

Improvebattery cell positioningVSAvoidvibration prevention

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The invention changes the binding bar shape from angled to a specific profile with a horizontal section that fits into the separator groove. This geometric parameter change enables the binding bar to effectively constrain up-and-down movement of the separator and battery cells, resolving the vibration issue while maintaining positioning stability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The groove structure acts as an intermediary element between the binding bar and the separator. Instead of the binding bar directly pressing on the separator (which causes distortion), the groove mediates the interaction by providing a geometric constraint that prevents up-and-down movement without applying damaging pressure

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8999555B2Battery array configured to prevent vibration

Publication Date: 2015.04.07 SANYO ELECTRIC CO LTD

AI summary

A battery array is provided with a battery stack (5) having a plurality of rectangular battery cells (1) stacked together with intervening separators (2), endplates (3) disposed at the ends of the battery stack, and binding bars (4) extending in the battery cell stacking direction and attached to the endplates in a manner that binds both sides of the battery stack. The binding bars are configured as plates of given width extending along the battery stack surfaces. The binding bars and separators fit together in a linked configuration that limits their relative movement in the up-and-down direction.