Battery Module Framing Assembly for Serviceable Compression Retention
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Solution Overview
Problem
Existing battery module assembly techniques require complex adhesives and welding for connecting end plates and side plates, making assembly difficult and disassembly challenging for serviceability and recycling.
Innovation Solution
A framing assembly for battery modules that uses end plates, side plates, locking plates, and fasteners to securely connect the plates, allowing for easy assembly and non-destructive disassembly, while maintaining compression of the battery cell stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives and welding are used to connect end plates and side plates, then the connection strength is improved, but the assembly complexity and difficulty increase
Solution Approach 1:
The patent replaces chemical bonding (adhesives) and thermal bonding (welding) with a mechanical fastening system consisting of locking plates, fasteners, and compression members. This mechanical system achieves strong connections while enabling easy disassembly, directly resolving the contradiction between connection strength and assembly complexity.
Solution Approach 2:
The connection system is divided into separate modular components: end plates, side plates, locking plates, fasteners, and compression members. This segmentation allows each component to be independently manufactured and assembled, reducing overall assembly complexity while maintaining connection strength through the coordinated interaction of these modular elements.
2Strength
If adhesives and welding are used to connect end plates and side plates, then the connection strength is improved, but the ease of disassembly for serviceability and recycling deteriorates
Solution Approach 1:
The patent replaces irreversible chemical and thermal bonding processes with reversible mechanical fastening. The locking plates with fasteners can be easily removed and reattached, and the compression members can be released to disassemble the structure, enabling serviceability and recycling while maintaining strong connections during operation.
Solution Approach 2:
The connection system transitions from a static, permanent bond (adhesive/weld) to a dynamic, adjustable mechanical connection. The compression members can be compressed to secure the connection during operation, then released to enable easy disassembly for serviceability and recycling, adapting the connection state based on operational requirements.
3Ease of operation
If a simple mechanical connection is used to connect end plates and side plates, then the ease of assembly is improved, but the connection strength and reliability deteriorate
Solution Approach 1:
The patent combines multiple mechanical elements (locking plates, fasteners, compression members) into an integrated connection system. This merging of components creates a reliable connection that maintains structural integrity while remaining easier to assemble than traditional adhesive or welding methods, as the mechanical elements can be quickly engaged and secured.
Solution Approach 2:
The compression members are configured to apply distributed compressive forces across the battery cell stacks, creating a uniform stress distribution that enhances connection reliability. The curved or angled geometry of these members optimizes force transmission while maintaining ease of assembly through simple insertion and engagement motions.
4Strength
If traditional assembly methods are used, then the structural integrity is maintained, but the productivity and assembly time decrease
Solution Approach 1:
The modular segmented design allows components to be pre-assembled and then quickly combined, reducing on-site assembly time. The standardized interfaces between end plates, side plates, and locking plates enable rapid assembly while maintaining structural integrity through the coordinated mechanical connection of these segments.
Solution Approach 2:
Components such as locking plates and compression members can be pre-positioned or pre-assembled before final assembly. This preliminary action reduces the complexity and time of the final assembly operation while ensuring that the structural integrity requirements are met through proper component configuration and alignment.
Data Source
AI summary
A framing assembly for a battery module having at least one battery cell stack. The framing assembly includes end plates for forming ends to the battery cell stack, side plates for forming sides to the battery cell stack, and locking plates for securing each end of the side plates to an end plate. The end plates have studs that project from the end plates, the side plates have open-ended slots to receive the studs and pins near the open-ended slots that project from the side plate. The locking plates have stud openings and pin openings that contain the studs and pins when securing the side plates to end plates. Fasteners engage with the studs to retain the locking plates on the studs and pins. Framing assembly maintains compression of the battery cell stacks.