Battery Module Circuit Board Mounting With Foamed Plastic Retainer
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Solution Overview
Problem
Existing battery module arrangements face challenges in optimally positioning the circuit board of a battery monitoring unit due to limited installation space and inefficient mounting methods, which can lead to suboptimal performance and increased weight.
Innovation Solution
A battery module arrangement featuring a holding element made of foamed plastic, such as expanded polypropylene, with a recess for the circuit board, positioned between two battery modules, and attached using resilient fastening elements, allowing for precise installation and vibration damping, while providing a weight advantage over metal elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal retaining element is used to hold the circuit board, then the structural strength and stability are improved, but the overall weight of the battery module arrangement increases
Solution Approach 1:
The patent changes the material parameter from metal to foamed plastic, transforming the retaining element from a heavy, rigid material to a lightweight, elastic material. This parameter change resolves the contradiction by maintaining sufficient mechanical strength through elasticity while dramatically reducing the weight of the battery module arrangement.
Solution Approach 2:
The patent uses foamed plastic as a composite material that combines lightweight properties with elastic characteristics. This composite material achieves both weight reduction and adequate structural performance, resolving the contradiction between strength and weight.
2Manufacturing precision
If the circuit board is mounted rigidly to maximize stability, then the positional accuracy is improved, but the ability to dampen vibrations is reduced
Solution Approach 1:
The patent changes the mechanical parameter of the retaining element from rigid to elastic. The elastic foamed plastic material can deform under vibration loads and return to its original shape, effectively dampening vibrations while maintaining the circuit board's positional accuracy through the elastic restoring force.
Solution Approach 2:
The patent applies beforehand cushioning by using the elastic foamed plastic retaining element that is pre-configured to absorb and dampen vibrations before they can affect the circuit board. This proactive vibration damping protects the circuit board while maintaining its positional accuracy.
3Manufacturing precision
If the holding element is designed with precise tolerances to ensure high positional accuracy, then the manufacturing precision is improved, but the ease of manufacture is reduced
Solution Approach 1:
The patent changes the material parameter to foamed plastic, which can be manufactured with sufficient tolerances through foam molding processes. The inherent elasticity of the foam material provides a tolerance buffer that maintains positional accuracy while simplifying the manufacturing process compared to precision-machined metal components.
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 enables optimal positioning of the circuit board with high positional accuracy, reduces weight, and effectively dampens vibrations, improving the overall performance and reliability of the battery module arrangement.
Implementation Method 1
foamed plastics have a high damping constant, so that the holding elements made of foamed plastic can dampen vibrations acting on the circuit board
Implementation Method 2
The expansion section can be arranged in a bore of the holding element
Data Source
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AI summary
Battery module arrangement comprising: a first battery module (8) and a second battery module (9), each comprising one or more battery cells, a circuit board (11) of a battery monitoring unit; and a retaining element (16) having a receptacle in which the circuit board (11) is arranged, characterized in that the retaining element (16) is arranged between the first battery module (8) and the second battery module (9).