Battery Module End Plate Structure for Thin, Rigid Lifting Support
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Solution Overview
Problem
Existing battery modules face challenges in maintaining rigidity and reducing thickness for efficient lifting, leading to reduced volume density due to localized weight concentration and increased thickness requirements for lifting mechanisms.
Innovation Solution
A battery module design featuring a wide contact area between the end plate and lifting device, with a lifting support portion having a horizontal support surface and open structure, and a central reinforcing rib to enhance rigidity, allowing for thin end plates and efficient space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lifting mechanism with a ball and lifting groove is used, then the battery module can be elevated, but the contact area is extremely small (point contact) and high rigidity is required
Solution Approach 1:
The patent replaces the ball contact mechanism with a curved surface contact mechanism. The lifting groove is designed with a curved bottom surface that contacts the ball, transforming point contact into surface contact. This curvature design increases the contact area while maintaining the lifting function, reducing the rigidity requirements of the end plate.
2Strength
If the thickness of the end plate is increased to increase rigidity, then the lifting groove can operate properly, but the space for battery cells is reduced
Solution Approach 1:
The patent applies local quality by concentrating the thickness increase only at the lifting groove region where rigidity is needed, while keeping the rest of the end plate thin. The lifting groove portion is designed with increased local thickness to provide sufficient rigidity for ball contact operation, while the overall end plate maintains minimal thickness to maximize battery cell accommodation space.
Solution Approach 2:
The patent resolves the thickness contradiction by utilizing the vertical dimension within the lifting groove structure. By designing the lifting groove with a curved bottom surface and appropriate depth, the necessary rigidity is achieved through the three-dimensional geometry of the groove itself rather than uniformly increasing the end plate thickness, thereby preserving volume for battery cells.
3Quantity of substance
If the weight of the battery module increases, then the capacity increases, but the number of lifting grooves must be increased
Solution Approach 1:
The patent merges multiple lifting functions into a single lifting groove by designing it with a curved bottom surface that can accommodate ball contact. This unified curved surface design allows one lifting groove to handle increased loads more effectively, reducing the need to add multiple lifting grooves when battery capacity and weight increase.
4Ease of operation
If a lifting mechanism is used instead of direct operator transport, then heavy battery modules can be moved, but the structure becomes more complex
Solution Approach 1:
The patent designs the lifting groove with a curved bottom surface that serves multiple functions: it provides ball contact for lifting, increases contact area to reduce rigidity requirements, and can accommodate variations in load weight. This multi-functional curved surface design eliminates the need for separate components, simplifying the overall structure while maintaining ease of operation for transporting heavy battery modules.
Data Source
AI summary
There is provided a battery module, in which a relatively wide contact area between an end plate and a lifting device may be secured when the battery module is elevated, the rigidity of the end plate may be sufficiently secured when the battery module is elevated, while forming a relatively thin end plate. The battery module includes a cell stack provided by stacking a plurality of battery cells, a module case accommodating the cell stack, an end plate disposed on front side and rear side of the module case, and a lifting support portion disposed on the end plate and having a support surface in surface contact with a lifting device.