Battery Module Middle Plate Layout for Cell Unit Heat and Swelling Isolation
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Solution Overview
Problem
The cell management unit in battery modules is vulnerable to failure due to swelling pressure and overheating from battery cells and busbars, leading to reliability issues.
Innovation Solution
A battery module design that incorporates a middle plate with an accommodating groove for the cell management unit, positioned between battery groups, which absorbs swelling pressure and keeps the unit away from direct heat sources, using elastic pads and fixing lugs for secure installation and heat insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cell management unit is disposed on the end plate, then the unit is easily accessible for installation, but the unit is deformed and fails under swelling pressure from battery cells
Solution Approach 1:
The cell management unit is extracted from the end plate and relocated to the middle plate, separating it from the swelling pressure zone. This allows the unit to be installed in a location free from mechanical stress while maintaining installation accessibility through the middle plate's accommodating groove structure.
Solution Approach 2:
The middle plate serves as an intermediary structure that houses the cell management unit away from both the swelling pressure of battery cells and the heat sources. The accommodating groove in the middle plate acts as a protective intermediary zone that isolates the unit from harmful environmental factors.
2Ease of operation
If the cell management unit is disposed on the harness separator above the battery cells, then the unit is easily installed, but the unit is heated resulting in high temperature
Solution Approach 1:
Instead of placing the cell management unit in the horizontal plane above battery cells (harness separator), the design moves it to a vertical dimension within the middle plate structure. This spatial repositioning removes the unit from the heat radiation zone while maintaining installation convenience through the middle plate's groove structure.
Solution Approach 2:
The middle plate with accommodating groove serves as a thermal intermediary, positioning the cell management unit at a distance from heat-generating battery cells and busbars. This intermediary placement reduces thermal exposure while maintaining operational accessibility.
3Volume of stationary object
If the cell management unit is disposed together with busbar on harness separator, then space utilization is improved, but the unit is exposed to heat from battery cells and busbar
Solution Approach 1:
The battery module structure is segmented into functional zones: battery cells at the bottom, middle plate with accommodating groove in the center, and end plates at the top. This segmentation separates the cell management unit from heat-generating components while maintaining efficient space utilization through vertical stacking.
Solution Approach 2:
The middle plate acts as a thermal intermediary barrier, positioning the cell management unit in a protected zone that is spatially separated from heat sources. This intermediary structure enables compact design while protecting the unit from thermal harm.
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 effectively prevents cell management unit deformation and overheating, enhancing its reliability by isolating it from swelling pressure and heat, thus improving the overall performance and longevity of the battery module.
Implementation Method 1
an elastic pad is disposed between the middle plate and the cell management unit... the elastic pad is pressed elastically along a thickness direction of the middle plate
Implementation Method 2
the cell management unit is disposed in an accommodating groove formed in the middle plate... prevents over-temperature caused by heating of the battery cells and the busbar
Data Source
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AI summary
This application relates to the field of battery technologies, and provides a battery module and a manufacturing method thereof. The battery module includes: two or more battery groups, where each battery group includes two or more battery cells; a module frame, including end plates and side plates, where the end plates and the side plates enclose an accommodating cavity for fixing the battery groups; a middle plate, where the middle plate is disposed between two of the battery groups, and is provided with an accommodating groove inside; and a cell management unit, disposed in the accommodating groove of the middle plate and connected to a sampling line of the battery cells. Disposing the cell management unit in the accommodating groove inside the middle plate can prevent the cell management unit from failing under swelling pressure of the battery cells. In addition, disposing the cell management unit in the middle plate can also prevent over-temperature caused by heating of the battery cells and a busbar, thereby greatly improving reliability of the cell management unit.