Battery Module Cover Structure for Thermal Expansion Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery modules, temperature changes cause cover bodies to expand or contract, compromising the insulation distance between battery cells and potentially leading to the cover bodies falling off, as existing designs fail to securely maintain the positional relation and insulation.
Innovation Solution
A battery module design featuring a first and second cover body with overlapping portions and a retainer, where the cover bodies are attached to an attachment-target member via binding bars and connection portions, allowing sliding movement to maintain insulation and prevent falling, with the retainer positioned centrally to enhance rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the cover body is made fixed and rigid to maintain structural stability, then the structural stability is improved, but the cover body cannot accommodate thermal expansion and contraction, causing insulation distance compromise and potential falling off
Solution Approach 1:
The cover body is designed with a sliding structure that allows it to move dynamically in response to thermal expansion and contraction. The sliding portion enables the cover body to adjust its position along the stacking direction while maintaining electrical insulation, thus accommodating thermal changes without compromising structural stability.
Solution Approach 2:
The cover body is divided into a fixed portion and a sliding portion. The fixed portion maintains structural stability and electrical insulation, while the sliding portion accommodates thermal expansion and contraction. This segmentation allows each part to perform its specific function effectively.
2Adaptability or versatility
If the cover body is made movable to accommodate thermal expansion and contraction, then the thermal adaptability is improved, but the structural stability and insulation distance may be compromised
Solution Approach 1:
The sliding structure allows the cover body to move dynamically in response to thermal changes while maintaining controlled movement within the insulation distance requirements. The movement is constrained to ensure structural stability is not compromised.
Solution Approach 2:
The sliding structure acts as an intermediary mechanism between the fixed cover body and the thermal environment. It mediates the thermal expansion and contraction forces, allowing the cover body to adapt thermally while maintaining structural integrity and insulation distance.
3Reliability
If the cover body is secured firmly to prevent falling off, then the attachment stability is improved, but the cover body cannot accommodate thermal expansion and contraction
Solution Approach 1:
The attachment structure is designed to be dynamically adjustable through the sliding mechanism. The cover body can move along the stacking direction to accommodate thermal changes while remaining attached to the case body, thus maintaining both attachment stability and thermal adaptability.
Solution Approach 2:
The attachment system is segmented into fixed attachment points and a sliding portion. The fixed attachment points ensure the cover body remains securely attached, while the sliding portion allows thermal expansion and contraction accommodation.
4Object-affected harmful factors
If the insulation distance is increased to ensure electrical safety, then the electrical insulation is improved, but the space for thermal expansion and contraction is reduced
Solution Approach 1:
The sliding structure allows the cover body to maintain a dynamic insulation distance that accommodates thermal expansion and contraction. The insulation distance is maintained within safe limits while allowing necessary movement for thermal adaptability.
Solution Approach 2:
The sliding mechanism acts as an intermediary that manages the relationship between insulation distance requirements and thermal expansion needs. It ensures the cover body maintains adequate insulation distance while allowing the necessary movement for thermal accommodation.
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 design effectively secures the insulation distance between battery cells and prevents cover bodies from falling off, while allowing for thermal expansion and contraction, thereby maintaining attachment stability and improving module rigidity.
Implementation Method 1
when a temperature of a case body is changed due to a temperature change of a battery cell, the cover body is expanded or contracted in accordance with its linear expansion coefficient
Data Source
AI summary
A battery module includes: a plurality of stacked battery cells; a first cover body and a second cover body provided to cover the plurality of battery cells in a direction orthogonal to a stacking direction of the battery cells; a pair of binding bars that restrain the plurality of battery cells in the stacking direction of the battery cells; and a retainer connected to each of the binding bars. The first cover body has a first overlapping portion. The second cover body has a second overlapping portion disposed between each of the battery cells and the first overlapping portion and overlapping with the first overlapping portion in a direction orthogonal to the stacking direction of the battery cells. The first cover body is disposed between each of the battery cells and the retainer in the direction orthogonal to the stacking direction of the battery cells.