Battery Module Connecting Bodies Prevent Cell Swelling Delamination
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Solution Overview
Problem
Battery modules comprising galvanic cells face issues with swelling due to aging effects and ion intercalation, leading to delamination of winding layers, which affects their service life and manufacturing complexity.
Innovation Solution
A battery module design featuring a plurality of galvanic cells connected by materially bonded and form-fitting connecting bodies, with a specific arrangement of prismatic cells and a connecting material that forms a composite component, enhancing rigidity and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanic cells are connected using conventional methods, then the battery module can be assembled, but the service life is reduced due to delamination of winding layers caused by swelling
Solution Approach 1:
The patent combines the connecting body and connecting material into an integrated composite component. The connecting material is cast into the connecting body, creating a merged structure that provides both mechanical connection and swelling compensation. This merging eliminates the need for separate connecting elements and improves reliability by preventing delamination through uniform swelling compensation across all galvanic cells.
Solution Approach 2:
The connecting material is designed with specific material parameters that enable it to compensate for swelling. The material properties are selected to match the thermal and mechanical expansion characteristics of the galvanic cells, allowing it to absorb and distribute swelling forces uniformly. This parameter optimization prevents delamination while maintaining structural integrity throughout the battery module's service life.
2Ease of manufacture
If conventional connecting methods are used, then assembly is possible, but manufacturing complexity increases and ease of manufacture decreases
Solution Approach 1:
By merging the connecting body and connecting material into a single composite component, the patent reduces the number of assembly steps. Instead of separately installing connecting elements and filling material, the integrated component is pre-formed and simply positioned between galvanic cells. This significantly simplifies the manufacturing process while reducing assembly complexity.
Solution Approach 2:
The connecting material is cast into the connecting body in advance, creating a pre-assembled composite component. This preliminary action eliminates the need for on-site material application and curing processes during battery module assembly. The pre-formed connecting bodies can be stored and installed as complete units, greatly simplifying the manufacturing workflow.
3Duration of action of moving object
If galvanic cells swell during operation, then ion intercalation occurs, but delamination of winding layers occurs reducing service life
Solution Approach 1:
The patent converts the harmful swelling effect into a beneficial force by designing the connecting material to actively compensate for volume changes. Instead of resisting swelling, the material is engineered to expand with the galvanic cells, distributing swelling forces uniformly and preventing delamination. This transforms a degradation mechanism into a protective function that extends service life.
Solution Approach 2:
The connecting material's physical and chemical parameters are optimized to match the swelling characteristics of galvanic cells. By selecting materials with compatible thermal expansion coefficients and compressibility, the system accommodates volume changes without creating delamination stresses. This parameter matching prevents harmful effects while maintaining structural integrity throughout the battery's operational life.
Data Source
AI summary
The invention relates to battery modules, battery devices and to methods for producing a battery module.