Battery Module Insert Element With Bending Compression Tubes
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Solution Overview
Problem
Existing swelling pads for battery cells are limited in flexibility and design, failing to effectively adjust load profiles to accommodate volume changes in battery cells, leading to potential damage and inefficiencies.
Innovation Solution
An insert element comprising two rigid cover plates and an intermediate layer with individually designed compression elements, featuring predetermined bending points that adjust their position under load to manage load distribution and volume changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional swelling pads made of foam-like materials are used between battery cells, then they can compensate for volume changes, but their behavior is limited by foam structure properties and cannot be adjusted or modified
Solution Approach 1:
The intermediate layer is segmented into a multiplicity of individual compression elements arranged distributed over the entire layer. Each compression element can be independently designed with specific bending points, allowing customized load distribution patterns while maintaining overall structural integrity. This segmentation enables adjustable load profiles without requiring complex monolithic structures.
Solution Approach 2:
The compression elements incorporate predetermined bending points that dynamically adjust their position and deformation characteristics under load. As the battery cells expand or contract, the bending points move and reposition, allowing the insert element to adapt its load distribution behavior in real-time. This dynamic response provides adjustability that static foam materials cannot achieve.
2Adaptability or versatility
If swelling pads with fixed foam structure are used, then manufacturing is simple, but the load distribution behavior cannot be customized or optimized for different applications
Solution Approach 1:
By dividing the intermediate layer into multiple discrete compression elements, each element can be manufactured using standardized processes while allowing customization of individual element characteristics through bending point placement. This segmentation enables modular manufacturing approaches that balance ease of production with design flexibility.
Solution Approach 2:
Different regions of the intermediate layer can have compression elements with different bending point configurations, densities, and geometries. This local quality variation allows customization of load distribution patterns for specific application requirements while maintaining consistent manufacturing processes across the entire insert element.
3Reliability
If rigid swelling pads are used to provide constant load, then they can protect against cell expansion damage, but they cannot adapt to varying volume changes and may cause stress concentrations
Solution Approach 1:
The compression elements with predetermined bending points provide dynamic adaptability while maintaining protective function. As battery cells undergo volume changes, the bending points move and the elements deform elastically, continuously adapting the load distribution to match the actual cell geometry. This ensures reliable protection without stress concentrations that would occur with fixed rigid structures.
Solution Approach 2:
The insert element changes its mechanical parameters (bending point positions, deformation patterns) in response to varying load conditions and cell volume changes. This parameter adaptability allows the system to maintain optimal protective characteristics across different operating conditions, enhancing reliability while responding dynamically to cell expansion and contraction.
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 insert element provides customizable load distribution and improved protection against cell damage by adapting to volume changes, enhancing flexibility and efficiency in load management.
Implementation Method 1
an intermediate layer which is arranged between the two cover plates, can be compressed elastically, and is constructed from a multiplicity of individual compression elements
Data Source
AI summary
The present disclosure relates to an insert element for insertion between two adjacent battery cells of a battery module, and to a battery module of this type. In order to improve insert elements of this type, in particular with regard to the flexibility of their use and their configuration, an insert element is proposed comprising two rigid cover plates and an intermediate layer which is arranged between the two cover plates, can be compressed elastically, and is constructed from a multiplicity of individual compression elements which are arranged distributed over the entire intermediate layer. The compression elements are each configured at least partially hose-shaped or tube-shaped, have at least one through bore in longitudinal direction and have one or more predetermined bending points in a region between the cover plates which move, in the case of compression of the intermediate layer by way of reduction of the spacing between the cover plates, in a direction transversely with respect to a connecting line between the cover plates.