Battery Module Coupling Structure for Higher Structural Rigidity
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Solution Overview
Problem
As battery modules increase in size and weight, their structural rigidity weakens, compromising their integrity and performance.
Innovation Solution
A battery module design that includes a coupling member with multiple coupling portions to securely connect battery cells, bus bars, and bus bar holders, enhancing structural rigidity through superior shear strength and distributed coupling points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are enlarged to increase capacity, then energy storage capability is improved, but structural rigidity deteriorates due to increased weight and size
Solution Approach 1:
The battery module is divided into multiple sub-modules, each with its own frame structure. This segmentation allows each sub-module to maintain structural rigidity independently while the overall module achieves increased energy storage capacity through modular expansion.
Solution Approach 2:
The frame structure utilizes composite materials with high strength-to-weight ratio to maintain structural rigidity while minimizing weight increase. This allows the battery module to be enlarged without proportionally increasing weight, thereby preserving structural rigidity.
2Ease of manufacture
If traditional welding methods are used to fix battery cells and frame, then assembly simplicity is improved, but structural rigidity deteriorates due to localized stress concentration
Solution Approach 1:
Coupling members are introduced as intermediary components between the battery cells and the frame structure. These coupling members distribute mechanical stresses across multiple contact points and prevent direct stress concentration at weld joints, thereby improving structural rigidity while maintaining assembly simplicity.
Solution Approach 2:
The coupling members extend in multiple spatial dimensions to connect battery cells with the frame structure, creating a three-dimensional coupling network. This multi-dimensional connection approach distributes forces more effectively compared to traditional single-point welding, enhancing structural rigidity without complicating the manufacturing process.
Data Source
AI summary
A battery module includes a number of battery cells, a bus bar at a side of the battery cells, a bus bar holder supporting the bus bar, a side plate on side surfaces of the battery cells, and a coupling member including a first coupling portion between the battery cells and the bus bar holder, a second coupling portion between the bus bar holder and the side plate, and a third coupling portion between the side plate and the battery cells. The coupling member couples the battery cells, the bus bar, and the bus bar holder together.