Lightweight Battery Module Casing for Capacity-Weight Balance
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Solution Overview
Problem
The increasing weight of battery modules in new energy vehicles due to larger capacities leads to an overall increase in vehicle weight, which is a challenge in optimizing vehicle endurance.
Innovation Solution
A battery module design with a protective casing comprising end plates and side plates forming an accommodating cavity for single cells, where the weight ratio of the casing to cells is optimized (0.05≤M2/M1≤0.25), along with adhesive and welding strengths, insulating films, and a lightweight design to balance weight and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the capacity of the battery module is increased to improve the endurance of new energy vehicles, then the energy storage capability is improved, but the weight of the battery module and vehicle increases
Solution Approach 1:
The patent changes the material parameters of the protective casing by using aluminum alloy materials with optimized thickness (5-15mm) and specific structural parameters (plate spacing, reinforcement distribution) to reduce the weight ratio of the casing to the battery cells to 5-25%, thereby reducing overall battery module weight while maintaining required capacity
Solution Approach 2:
The patent employs composite structural design combining aluminum alloy end plates with reinforced rib structures, and uses composite material systems (aluminum alloy + adhesive layers + insulating films) to achieve optimal strength-to-weight ratio, reducing casing weight without compromising safety or structural integrity
2Weight of moving object
If the weight of the protective casing is reduced to decrease battery module weight, then the vehicle weight is reduced, but the safety and structural integrity may be compromised
Solution Approach 1:
The protective casing is segmented into multiple functional components (end plates, side plates, reinforcement ribs, adhesive layers, insulating films) that work together to provide both weight reduction and safety. The segmentation allows each component to be optimized for its specific function while collectively maintaining structural integrity
Solution Approach 2:
The patent incorporates buffer structures, adhesive layers, and insulating films as preventive safety measures that cushion and protect the battery cells from mechanical shocks, vibrations, and thermal effects before harmful events occur, ensuring safety even with reduced casing weight
3Reliability
If the structural complexity is increased to improve safety and structural integrity, then the reliability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The protective casing structure is designed with multi-functionality where the aluminum alloy plates serve multiple purposes: structural support, thermal management interface, mechanical protection, and crashworthiness. The reinforcement ribs provide both structural strengthening and attachment points for thermal management components, reducing the need for separate dedicated structures
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 design reduces the impact of the battery module's weight on the vehicle, maintaining a balanced gravimetric energy density and safety by optimizing the weight ratio and structural integrity of the battery module and pack.
Implementation Method 1
an adhesive layer is provided between the single cell and the side plate
Implementation Method 2
two ends of the side plate are respectively welded and fixed to the first end plate and the second end plate
Data Source
AI summary
A battery module and a battery pack, where the battery module has a first direction, a second direction and a third direction that intersect with each other pairwise. The battery module includes a plurality of single cells and a protective casing. The protective casing includes a top cover, a first end plate, a second end plate and a plurality of side plates, where the first end plate and the second end plate are arranged at intervals along the first direction; the plurality of side plates are arranged at intervals along the second direction and connected between the first end plate and the second end plate; the top cover is connected to a same side of the first end plate, the second end plate and the two side plates along the third direction, and together they define an accommodating cavity.