Battery Module Clamping Assembly for Stable Cell Compression
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Solution Overview
Problem
Conventional battery module assembly methods face challenges due to complex tolerance chains, increased material costs, and inefficiencies in mechanical support, particularly in handling swelling forces and corrosion resistance, leading to higher weight and lower packing efficiency.
Innovation Solution
A battery module design utilizing a connecting system with adjustable end and side plates connected by joining elements and clamping elements, allowing for variable distance adjustment and eliminating the need for welding, thereby using high-strength steel and ensuring corrosion protection without additional coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional mechanical support structures (side plates and end plates) are used to support all integrated components, then mechanical stability is achieved, but device complexity and material costs increase
Solution Approach 1:
The patent combines the functions of side plates and end plates into a single integrated housing structure. The housing comprises side walls extending between first and second end walls, eliminating the need for separate side plates and end plates. This merging reduces the number of components, simplifies assembly, and lowers material costs while maintaining mechanical stability through the integrated structural design.
2Stability of the object's composition
If battery cells are compressed to a specific force to account for tolerance chains, then mechanical stability is improved, but manufacturing precision requirements increase and assembly complexity increases
Solution Approach 1:
The patent incorporates a compression force adjustment mechanism that allows the compression force applied to the battery cells to be dynamically adjusted during assembly. This mechanism compensates for variations in manufacturing tolerances of individual components, enabling the achievement of stable compression forces without requiring extremely precise manufacturing. The adjustable nature of the mechanism provides flexibility to accommodate tolerance chains while maintaining consistent compression.
3Strength
If welding is used to connect end plates and side plates, then mechanical strength is improved, but corrosion resistance deteriorates due to coating damage
Solution Approach 1:
The patent replaces the welding process with a mechanical connection system. The integrated housing structure utilizes interlocking features, threaded fasteners, or press-fit connections to join the side walls and end walls. This mechanical connection system achieves sufficient joint strength without the need for welding, thereby preserving the protective coatings on the metal surfaces and maintaining corrosion resistance. The design eliminates thermal processes that would damage anti-corrosion coatings.
4Object-affected harmful factors
If additional corrosion protection coatings are applied to metal components, then corrosion resistance is improved, but material costs and manufacturing complexity increase
Solution Approach 1:
The patent designs the housing and other metal components from corrosion-resistant materials that inherently provide protection without requiring additional coatings. The housing may be constructed from stainless steel, aluminum alloys, or other corrosion-resistant materials that maintain their protective properties through their material composition alone. This self-service approach to corrosion resistance eliminates the need for separate coating application processes, reducing manufacturing steps and costs while maintaining adequate corrosion protection.
Data Source
AI summary
A battery module includes: a first end plate and a second end plate; a plurality of cells arranged between the first and the second end plates in a stacking direction; a plurality of side plates, a first end of each of the side plates being connected to the first end plate, and a second end of each of the side plates being connected to the second end plate; and a connecting system including a first joining element in the first end plate, a second joining element in one of the side plates, and a clamping element. The connecting system connects the first end of the one of the side plates and the first end plate by the first joining element, the second joining element, and the clamping element, and the connecting system is configured to vary a distance of the first end plate with respect to the second end plate by varying a relative position of the clamping element, the first joining element, and the second joining element with respect to each other.