Battery Module End Separator for Displacement and Reaction Force Control

Solution Overview

Problem

Existing battery modules face issues with battery displacement and excessive reaction forces due to dimensional changes and collision loads, which can lead to damage of bus bars and end plates.

Innovation Solution

A battery module design incorporating an end separator with a first support member supporting the battery's peripheral edge and a second support member with lower rigidity, which absorbs displacement and reduces reaction forces through elastic deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a spring is displaced in the stacking direction to suppress excessive reaction force, then the reaction force is reduced, but the battery is largely displaced with the spring displacement under impact load, causing bus bar damage

Engineering Contradiction:

Improvereaction forceVSAvoidbus bar damage

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The end separator is divided into multiple functional regions: a first support member supporting the peripheral edge, a second support member supporting the central part with lower rigidity, and a third support member. This segmentation allows different parts to handle different types of loads - the peripheral support members resist collision loads to prevent battery displacement, while the central support member with lower rigidity absorbs expansion forces to reduce reaction forces on the battery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the end separator are given different rigidity characteristics. The first support member at the peripheral edge has higher rigidity to resist collision loads, while the second support member at the central part has lower rigidity to accommodate battery expansion. This local differentiation of mechanical properties allows the structure to simultaneously prevent displacement and reduce reaction forces.

Inventive Principle:

Principle #3Local quality

2Reliability

If the end separator has high rigidity to suppress battery displacement, then displacement is reduced, but the reaction force increases, potentially causing battery breakage

Engineering Contradiction:

Improvebattery displacementVSAvoidreaction force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The end separator is divided into multiple functional regions: a first support member supporting the peripheral edge, a second support member supporting the central part with lower rigidity, and a third support member. This segmentation allows different parts to handle different types of loads - the peripheral support members resist collision loads to prevent battery displacement, while the central support member with lower rigidity absorbs expansion forces to reduce reaction forces on the battery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the end separator are given different rigidity characteristics. The first support member at the peripheral edge has higher rigidity to resist collision loads, while the second support member at the central part has lower rigidity to accommodate battery expansion. This local differentiation of mechanical properties allows the structure to simultaneously prevent displacement and reduce reaction forces.

Inventive Principle:

Principle #3Local quality

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 suppresses battery displacement and reduces reaction forces during collision loads, minimizing damage to bus bars and maintaining structural integrity.

Implementation Method 1

a second support member that supports a central part of the surface and has lower rigidity with respect to deformation in the stacking direction than the first support member

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12531265B2Battery module

Publication Date: 2026.01.20 SANYO ELECTRIC CO LTD

AI summary

A battery module includes: battery stack in which a plurality of batteries are stacked; end plate provided outside battery at an end in a stacking direction of the plurality of batteries; and end separator provided between battery at the end and end plate, end separator including first support member that supports a peripheral edge of a surface intersecting the stacking direction of battery at the end, and second support member that supports a central part of the surface and has lower rigidity with respect to deformation in the stacking direction than first support member.