Battery Module Clamping Assembly for Tolerance-Stable Compression
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Solution Overview
Problem
Conventional battery module assembly methods face challenges due to complex tolerance chains, requiring precise compression forces and materials with high yield strength to withstand swelling forces, leading to increased costs and inefficiencies.
Innovation Solution
A battery module design using a connecting system with first and second joining elements and a clamping element that adjusts the distance between end plates, allowing for variable compression forces and eliminating the need for welding, thereby using high-strength steels with thinner walls and corrosion-resistant coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding methods are used to fix end plates, then mechanical connection is achieved, but material costs increase due to requirement of high-yield-strength materials and corrosion protection coatings
Solution Approach 1:
The patent replaces conventional welding (thermal/mechanical system) with a purely mechanical connecting system consisting of joining elements and clamping elements. This substitution eliminates the need for high-yield-strength materials and corrosion-resistant coatings required for welding applications, thereby reducing material costs while maintaining connection strength.
2Stability of the object's composition
If compression force is applied to compensate for tolerance chains, then assembly stability is improved, but the complexity of defining force windows increases
Solution Approach 1:
The patent introduces adjustable connecting elements that can adapt to different positions and tolerance variations dynamically. Instead of relying on complex force window calculations, the system allows for position adjustment of joining and clamping elements, transforming a static tolerance compensation approach into a dynamic adaptation mechanism that simplifies the assembly process.
3Strength
If side plates and end plates are used to support all components, then mechanical support is achieved, but the weight of the battery module increases
Solution Approach 1:
The patent segments the support function by introducing dedicated joining elements and clamping elements that work together in a distributed manner. Instead of relying on heavy side plates and end plates to provide all support, the segmented connecting system distributes mechanical support functions across multiple lightweight elements, reducing overall weight while maintaining structural integrity.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
The present disclosure refers to a battery module (100). The battery module (100) includes a first and a second end plates (110, 120). Between the first and the second end plates (110, 120) cells (150) are stacked in a stacking direction. Further, the battery module (100) includes side plates (130, 140), wherein a first end (132) of each of the side plates (130, 140) is connected to the first end plate (110) and a second end of each of the side plates (130, 140) is connected to the second end plate (120). In addition the battery module (100) includes at least one connecting system including a first joining element (111) assigned to the first end plate (110) and a second joining element (131) assigned to one of the side plates (130, 140) and a clamping element (180), wherein the connecting system provides the connection between the first end (132) of the one of the side plates (130, 140) and the first end plate (110) by the first joining element (111), the second joining element (131) and the clamping element (180) and is configured to adjust a distance of the first end plate (110) to the second end plate (120) depending on the relative position of the clamping element (180), the first joining element (111) and the second joining element (131) to each other. The invention further relates to an electric vehicle including the battery module (100) according to the invention and a method for assembly of a battery module (100).