Battery Module Cushion Assembly for Uniform Cell Stack Pressure
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Solution Overview
Problem
Existing battery modules experience uneven surface pressure distribution and assembly challenges due to the expansion of battery cells, leading to potential damage and difficulty in assembling the restriction units.
Innovation Solution
A manufacturing method for a battery module using a cushion material composed of a first elastic member with a frame-shaped member, a second elastic member with wave-shaped plate springs, and a third elastic member, where the second elastic member is formed by stacking wave-shaped plate springs inside the first elastic member, and the third elastic member is formed by foaming resin within the first elastic member, ensuring uniform surface pressure and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wave-shaped plate springs are arranged between the first plate and the second plate to cushion battery cell expansion, then the cushioning effect is improved, but large difference in surface pressure occurs between contact and non-contact portions, reducing uniformity in surface pressure
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the wave-shaped plate springs and the first/second plates. This resin layer fills the gaps and transmits pressure uniformly across the entire contact surface, eliminating the pressure concentration at specific contact points while maintaining the cushioning function of the wave-shaped springs.
Solution Approach 2:
The resin layer is designed to distribute pressure homogeneously across the surface. By using a compliant material that conforms to the surface geometry, the pressure distribution is equalized between the contact portions and non-contact portions of the wave-shaped plate springs, achieving uniform surface pressure throughout the assembly.
2Reliability
If wave-shaped plate springs are arranged between the first plate and the second plate, then cushioning function is provided, but positional deviation occurs during assembly, making assembly difficult
Solution Approach 1:
The resin layer serves as a compliant intermediary that absorbs positional deviations and misalignments during assembly. Its soft, deformable nature allows the wave-shaped plate springs to be positioned without requiring precise alignment, as the resin conforms to the actual contact surfaces and maintains the cushioning function regardless of minor positional variations.
Solution Approach 2:
The resin layer's material parameters (viscosity, elasticity, compliance) are selected to optimize assembly ease. During assembly, the resin remains sufficiently soft to accommodate positional deviations, and after assembly, it maintains sufficient rigidity to provide stable support and uniform pressure distribution, thus resolving the assembly difficulty while preserving the cushioning function.
3Reliability
If restriction units are compressed due to battery cell expansion, then the restriction function is activated, but the large surface pressure difference reduces the effectiveness of the restriction
Solution Approach 1:
The resin layer acts as a pressure-distributing intermediary between the compression force from battery cell expansion and the wave-shaped plate springs. It transforms the concentrated contact pressure into a distributed uniform pressure across the entire surface of the restriction unit, ensuring the restriction function is activated uniformly and effectively throughout the structure.
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 method enhances uniformity in surface pressure and simplifies the assembly process by preventing positional deviation and resin intrusion, thereby reducing damage to the battery module.
Implementation Method 1
a second elastic member having wave-shaped plate springs stacked in the stacking direction of the battery cell stack
Implementation Method 2
a step of forming the third elastic member by foaming and molding resin inside the first elastic member where the second elastic member is formed
Data Source
AI summary
There is provided a manufacturing method of a battery module, the battery module including a battery cell stack including a stack of a plurality of battery cells, a pair of plate-shaped members provided at both ends of the battery cell stack in a stacking direction, and a cushion material arranged between the plurality of battery cells and/or between the battery cell stack and the plate-shaped members, the cushion material including a first elastic member having a frame-shaped member arranged on an outer circumferential portion, a second elastic member arranged inside the first elastic member, and a third elastic member arranged on both sides of the battery cell stack in the stacking direction of the battery cell stack, the second elastic member having wave-shaped plate springs stacked in the stacking direction of the battery cell stack, the manufacturing method including.