Two-Stage Battery Module End Plate for Cell Swelling Bias Control
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Solution Overview
Problem
Existing battery module housings fail to optimally absorb swelling forces of battery cells during charging and discharging, leading to reduced capacity and life due to rigid end plates that restrict expansion, causing increased pressure and potential cell membrane rupture.
Innovation Solution
A two-part end plate design featuring an inner and outer profile element that adjusts rigidity and bias on battery cells in two stages, allowing for controlled expansion while maintaining a desired bias, with the inner profile element providing a first bias within a deformation path and the interaction with the outer profile element increasing rigidity and applying a second bias beyond that path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid end plate is used to clamp battery cells, then the structural stability and bias on battery cells is improved, but the battery cells cannot expand during charging/discharging leading to increased swelling forces and reduced cell life
Solution Approach 1:
The end plate is segmented into an inner profile element and an outer profile element that can move relative to each other. The inner profile element is divided into multiple segments that can independently deform to accommodate cell expansion while the outer profile element maintains overall structural stability. This segmentation allows the end plate to provide bias force while permitting controlled cell expansion.
Solution Approach 2:
The end plate transitions from a static rigid structure to a dynamic structure where the inner profile element can deform and adjust its rigidity. The inner profile element is designed to be flexible within a first deformation path to allow cell expansion, and becomes more rigid beyond that path to maintain structural stability. This dynamic adaptation resolves the contradiction between stability and cell life.
2Object-affected harmful factors
If a rigid end plate is used to prevent cell membrane rupture, then the protection against swelling forces is improved, but the battery cell capacity and life are reduced due to inability to breathe
Solution Approach 1:
The end plate's rigidity parameter is changed dynamically through the two-stage deformation mechanism. Within the first deformation path, the inner profile element has lower rigidity to allow cell expansion and breathing. Beyond this path, the rigidity increases as the inner and outer profile elements interact, providing stronger protection. This parameter change resolves the contradiction between protection and cell life.
Solution Approach 2:
The inner profile element acts as an intermediary between the battery cells and the outer profile element. It mediates the interaction by first allowing controlled expansion through its own deformation, then engaging with the outer profile element to provide additional support. This intermediary mechanism protects cells from excessive swelling forces while maintaining cell life.
3Force
If the end plate rigidity is increased to maintain bias on battery cells, then the structural support is improved, but the swelling forces are not optimally absorbed leading to increased pressure on cells
Solution Approach 1:
The end plate's rigidity is made dynamic rather than static. The inner profile element provides initial bias force with flexible deformation capability, absorbing swelling forces through elastic deformation. As deformation exceeds the first path, the interaction with the outer profile element increases rigidity and bias force. This dynamic behavior optimally manages both bias and pressure throughout the cell's operational life.
Solution Approach 2:
The inner profile element is designed with a first deformation path that acts as a cushioning mechanism before the full rigidity of the outer profile element engages. This beforehand cushioning absorbs initial swelling forces through elastic deformation, reducing peak pressures on the cells while maintaining necessary bias. The progressive engagement of the outer profile element provides additional cushioning as needed.
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
This design enhances the functionality and life of battery cells by allowing controlled expansion and absorption of swelling forces, maintaining optimal bias and preventing cell damage, thus improving the overall performance and longevity of the battery module.
Implementation Method 1
the inner profile element is formed and designed such that, within a first deformation path, it provides a first elastic bias on battery cells arranged in the housing
Implementation Method 2
the inner profile element and the outer profile element are formed and designed such that, once the first deformation path is exceeded, the inner profile element interacts with the outer profile element to exert a second elastic bias on battery cells arranged in the housing
Data Source
AI summary
A housing for a battery module for receiving battery cells, comprising at least one end plate made up of an inner profile element and an outer profile element, where the inner profile element is formed and designed such that, within a first deformation path, it provides a first elastic bias on battery cells arranged in the housing, and where the inner profile element and the outer profile element are formed and designed such that, once the first deformation path is exceeded, the inner profile element interacts with the outer profile element to exert a second elastic bias on battery cells arranged in the housing.