Battery Module End Separator for Aging Expansion Loads

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Solution Overview

Problem

The dimensional variation of batteries in a battery module due to aging causes a load on end plates, leading to potential failure through reaction forces, which existing technologies fail to adequately address.

Innovation Solution

Incorporating an end separator with a deformation allowing part that allows greater creep deformation than other parts, reducing the reaction force in the stacking direction by absorbing dimensional changes and distributing loads uniformly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If batteries are stacked to form a battery module, then high output voltage is achieved, but dimensional variation due to aging causes load on end plates leading to potential failure

Engineering Contradiction:

Improveoutput voltageVSAvoidbattery module safety

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The end separator incorporates a deformation allowing part with specific material properties that differ from other parts, enabling localized creep deformation at the deformation allowing part to absorb dimensional changes and reduce reaction forces on batteries, while maintaining structural integrity elsewhere

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The deformation allowing part is designed with controlled creep deformation characteristics, allowing it to gradually deform over time to accommodate battery expansion while reducing the reaction force transmitted to the end plates and batteries

Inventive Principle:

Principle #35Parameter changes

2Strength

If rigid structure is used to maintain structural integrity, then strength is improved, but reaction force from dimensional variation causes battery breakage

Engineering Contradiction:

Improvestructural integrityVSAvoidreaction force

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The deformation allowing part acts as a pre-designed cushioning element that anticipates and absorbs the dimensional changes of batteries during aging, reducing the harmful reaction forces before they can cause battery breakage

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Enhances the safety of the battery module by reducing reaction forces and maintaining structural integrity despite aging-related expansions, while also allowing for air cooling and potentially lowering manufacturing costs.

Implementation Method 1

an end separator provided between the battery at the end and the end plate, the end separator being disposed in a part in the stacking direction and including a deformation allowing part in which deformation due to creep is larger than deformation of other parts

Methodology Applied

Scientific EffectCreep: Creep

Data Source

PatentUS12489168B2Battery module

Publication Date: 2025.12.02 SANYO ELECTRIC CO LTD

AI summary

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, the end separator being disposed in a part in the stacking direction and including deformation allowing part in which deformation due to creep is larger than deformation of other parts.