Battery Module Bent Support Load Distribution
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Solution Overview
Problem
High-power battery modules face issues with reliability due to shape changes caused by gas generation in battery cells, leading to unstable cell fixation and reduced productivity, and there is a need to minimize size and weight while enhancing load distribution.
Innovation Solution
A battery module design featuring end and bottom plates with bent support portions that distribute the load of battery cells, using materials like SUS for rigidity and plastic for weight reduction, with enhanced fastening mechanisms to stabilize the module against vibrations and impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are connected in series to form a high-power battery module, then energy density and power output are improved, but gas generation from electrochemical reactions causes shape changes that reduce fixation stability and reliability
Solution Approach 1:
The battery module housing is segmented into multiple functional components: a base plate for load bearing, vertical plates for structural support, and end plates for cell fixation. This segmentation allows each component to address specific issues - the base plate handles load distribution while end plates with clamping structures address cell fixation stability despite shape changes from gas generation
Solution Approach 2:
The end plates incorporate adjustable clamping structures that can adapt to shape changes in battery cells caused by gas generation. The clamping force and positioning parameters can be modified to maintain secure fixation even when cell dimensions change during operation, thereby preserving reliability while maintaining high power output
2Reliability
If the housing structure is strengthened to improve reliability, then fixation stability is improved, but the size and weight of the battery module increase
Solution Approach 1:
The housing structure utilizes composite material construction combining high-strength metals (such as aluminum alloys or stainless steel) for critical load-bearing components like the base plate and vertical plates, while lighter materials are used for less critical parts. This composite approach achieves the required housing strength and fixation stability without proportionally increasing the overall module weight
Solution Approach 2:
The vertical plates and end plates incorporate curved or bent support portions rather than purely linear structures. These curved elements provide enhanced structural strength and load distribution capability while using less material than straight rigid supports, thereby improving reliability without proportionally increasing weight
3Strength
If materials with high rigidity like SUS are used to strengthen the housing, then structural strength is improved, but weight and cost increase compared to plastic materials
Solution Approach 1:
High-rigidity materials like SUS (stainless steel) are applied locally only where structurally critical - specifically in the base plate for load bearing, vertical plates for structural support, and clamping regions of end plates for cell fixation. Non-critical housing components use lighter plastic materials, achieving necessary structural strength while minimizing overall weight and cost
Data Source
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Figure 3A
AI summary
A battery module includes a plurality of battery cells stacked together; first and second end plates located at a first end and a second end, respectively, of the stacked battery cells; and side plates and a bottom plate coupled to the first and second end plates, wherein at least one of the first end plate and the second end plate has a bent support portion that overlaps with at least a portion of the bottom plate.