Battery Module Cable Deformation Management
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Solution Overview
Problem
In battery modules, the expansion of battery cells due to repetitive charging and discharging causes stress on connecting members and cables, leading to potential damage or breakage, especially when the cover members move relative to each other, resulting in taut or flapping cables that may break or contact surrounding components.
Innovation Solution
A battery module design featuring a cover with movable first and second cover members and a cable with a bent portion supported by multiple support portions, allowing the cable to deform and maintain its shape during relative movement, preventing tautness and flapping, thus protecting the cable from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover members are made movable to accommodate battery cell expansion, then the reliability of the battery module is improved, but the cable may become taut or flap, leading to cable breakage
Solution Approach 1:
The patent uses a flexible cable with a bent portion that can deform to accommodate the relative movement between the first and second cover members. This flexible design allows the cable to absorb the expansion and contraction of battery cells without becoming taut or flapping, thereby preventing cable breakage while maintaining battery module reliability
Solution Approach 2:
The patent makes the cable configuration dynamic by introducing a bent portion that can change shape in response to cover member movement. The cable transitions from a fixed rigid structure to a dynamic flexible structure that adapts to the expanding and contracting battery cells, resolving the contradiction between cover movability and cable integrity
2Strength
If the cable is made slack to prevent tautness during cover movement, then cable breakage is prevented, but the cable may flap and contact surrounding electronic components
Solution Approach 1:
The patent resolves the cable flapping issue by adding a bent portion that introduces a new spatial dimension for cable routing. This three-dimensional configuration allows the cable to accommodate cover member movement without excessive slack, preventing both tautness and flapping by utilizing vertical and lateral space rather than relying solely on horizontal cable length
3Stability of the object's composition
If the cable is made taut to prevent flapping, then cable stability is improved, but the cable may break due to excessive tension during cover movement
Solution Approach 1:
The flexible cable with bent portion design provides inherent stability through its geometric configuration rather than tension. The bent portion acts as a mechanical buffer that maintains cable positioning and stability while allowing controlled deformation, eliminating the need for excessive tension that would compromise cable strength
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 restricts cable breakage and flapping, ensuring reliable electrical connections between electronic components by maintaining the cable's shape and preventing excessive tension or slack, thereby enhancing the module's operational stability.
Implementation Method 1
an elastic body which is sandwiched between one of the two end plates and one of the battery cells and is elastically deformed as the battery cells expand
Data Source
AI summary
A battery module includes battery cells arranged side by side, two end plates sandwiching the battery cells, an elastic body, and a cover. The cover includes a first cover member and a second cover member. The battery module includes a cable that electrically connects a first electronic component and a second electronic component to each other. The cable has a bent portion capable of being deformed in accordance with relative movement between the first cover member and the second cover member in the arrangement direction. The cover includes support portions that support the cable to maintain the shape of the bent portion.