Battery Module Compression Frame for Uniform Li-Ion Cell Pressure
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Solution Overview
Problem
Current battery module designs for prismatic, blade, and pouch lithium-ion cells face inefficiencies due to complex constructions that reduce energy density, hinder thermal management, and lack precise control over compression forces, leading to performance and reliability issues in heavy-duty work machinery.
Innovation Solution
A battery module design featuring a frame with a compression plate and stopper system that applies uniform compression pressure to lithium-ion cells, mitigating bulging and ensuring consistent electrical output through a modular, unitary structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If restraining members (sheets, straps, metal strips, tie rods) are used to maintain compression on lithium-ion cells, then the cells maintain structural integrity and compression, but the device complexity increases due to multiple components and the volumetric energy density decreases
Solution Approach 1:
The patent combines the compression function and the structural frame into a single integrated compression frame that directly contacts and compresses the lithium-ion cells. This eliminates the need for separate restraining members such as sheets, straps, metal strips, and tie rods, thereby reducing the number of components while maintaining the necessary compression force on the cells throughout their operational lifecycle.
2Reliability
If restraining members are used to maintain compression on lithium-ion cells, then the cells maintain structural integrity, but the thermal management efficiency decreases due to reduced cooling surface area and increased thermal resistance
Solution Approach 1:
The compression frame is designed to directly contact the lithium-ion cells without intervening restraining members, eliminating thermal barriers between the cells and the cooling system. This integration ensures optimal thermal contact and heat dissipation while maintaining the necessary compression force on the cells.
3Force
If multiple load adjusting screws are used to compress the cell stack, then compression force can be applied, but the manufacturing precision decreases due to manual tuning requirements and uneven pressure distribution
Solution Approach 1:
The patent removes the manual load adjusting screws and their associated manual tuning process entirely. Instead, the compression force is applied through a pre-configured compression frame structure that provides uniform pressure distribution across all cells from the outset, eliminating the need for post-assembly manual adjustments and ensuring consistent compression throughout the battery module.
4Strength
If a box-in-box construction is used for the battery module, then structural protection is provided, but the volumetric energy density and gravimetric energy density decrease
Solution Approach 1:
The patent integrates the compression function directly into the structural frame of the battery module, eliminating the need for a separate inner box structure to hold the cells. This integration removes the redundant structural layers, increases the active cell volume proportion, and improves both volumetric and gravimetric energy density while maintaining adequate structural protection through the optimized frame design.
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 enhances energy density, improves thermal management, and extends the lifespan of lithium-ion cells by maintaining uniform pressure distribution and structural integrity, suitable for heavy-duty applications.
Implementation Method 1
a compression plate attached to the frame and configured to apply a uniform compression pressure to the plurality of lithium-ion cells in the frame
Data Source
AI summary
A battery module is disclosed. The battery module comprises: a frame; a plurality of lithium-ion cells provided in the frame; a compression plate attached to the frame and configured to apply a uniform compression pressure to the plurality of lithium-ion cells in the frame; and a stopper for holding the compression plate at a holding location for maintaining pressure.