Battery Module Absorption Element Deformation Zone

Solution Overview

Problem

Existing battery modules for motor vehicles face challenges in protecting electrical energy stores from damage due to high acceleration forces or deformation during impacts, as current energy absorption solutions are complex and do not effectively absorb all deformation energy, potentially causing mechanical stress on the battery.

Innovation Solution

A battery module design featuring a rigid battery frame with an absorption element fixed by connecting sections, maintaining a distance between the absorption element and the frame to form a deformation zone, allowing the absorption element to absorb impact energy without mechanical force on the battery cell, thus protecting it with low technical complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If energy absorption elements are added to protect the electrical energy store, then protection against damage is improved, but device complexity increases and manufacturing becomes more complicated

Engineering Contradiction:

Improveprotection against damageVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The absorption element is divided into multiple fixing sections that are distributed around the battery frame. This segmentation allows the absorption element to be securely attached at multiple points while maintaining overall structural simplicity and enabling effective energy absorption without excessive complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The absorption element is positioned at a predetermined distance from the battery frame to create a deformation zone in advance. This pre-established cushioning space allows the absorption element to deform and absorb impact energy before any force reaches the battery frame, providing proactive protection rather than reactive

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Device complexity

If absorption elements are positioned close to the battery frame, then device complexity is reduced, but protection effectiveness decreases as deformation energy cannot be fully absorbed

Engineering Contradiction:

Improvedevice complexityVSAvoidprotection effectiveness

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The absorption element is positioned at a predetermined distance from the battery frame to create a deformation zone in advance. This pre-established cushioning space allows the absorption element to deform and absorb impact energy before any force reaches the battery frame, providing proactive protection rather than reactive

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The solution introduces a spatial dimension (distance) between the absorption element and battery frame that creates a deformation zone. This dimensional approach allows energy absorption to occur in the space between components rather than requiring direct contact, effectively separating the absorption function from the protection target

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If the absorption element is fixed directly to the battery frame, then manufacturing simplicity is improved, but the battery cell is subjected to mechanical force during impact

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmechanical force on battery

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The absorption element is positioned at a predetermined distance from the battery frame to create a deformation zone in advance. This pre-established cushioning space allows the absorption element to deform and absorb impact energy before any force reaches the battery frame, providing proactive protection rather than reactive

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The hollow space/deformation zone acts as an intermediary between the absorption element and the battery frame. This intermediate space allows the absorption element to perform its energy absorption function without directly transmitting mechanical forces to the battery frame, effectively decoupling the two components while maintaining their functional relationship

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively protects the battery cell from damage during impacts by allowing the absorption element to absorb deformation energy without damaging the battery, enhancing the battery module's stability and reducing manufacturing complexity.

Implementation Method 1

the absorption element can initially absorb deformation energy without mechanical force being exerted on the battery frame and the battery cell

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9911952B2Battery module for a motor vehicle

Publication Date: 2018.03.06 DR ING H C F PORSCHE AG

AI summary

A battery module (10) for a motor vehicle has at least one battery cell (12) for producing and storing electrical energy and a rigid battery frame (14) in which the at least one battery cell (12) is accommodated. An absorption element (24) is secured to the battery frame (14) by connection sections (28). The absorption element (24) is spaced apart from the battery frame (14) in such a way that a cavity (26) is formed between the absorption element (24) and the battery frame (14).