Load-Bearing Battery Module With Spring Deformation Space
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Solution Overview
Problem
Conventional battery modules for motor vehicles face challenges in protecting battery cells from external mechanical stresses, such as crashes, while also managing swelling and heat dissipation effectively, often resulting in increased risks of fires or explosions due to deformation and inadequate cooling.
Innovation Solution
A load-bearing battery module design featuring a module housing with spring devices between side walls and the cell stack, a cooling device between the cell pack and the module cover, and a support device within the housing to create deformation spaces and distribute forces, thereby reducing the risk of damage from mechanical loads and enhancing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the module housing is designed with rigid components and additional webs to protect battery cells from external influences, then the protection against mechanical loads is improved, but the volume of the module housing increases and the power and energy density decrease
Solution Approach 1:
The patent employs a flexible membrane structure that can deform under mechanical load to absorb external influences, while maintaining a compact housing design. The membrane acts as a protective barrier that accommodates deformation without requiring additional rigid structural elements, thus protecting battery cells while minimizing housing volume increase.
2Productivity
If structural components of the module housing are designed to save space and minimize redundancies, then the power and energy density are improved, but the protection against mechanical loads and the space for cables and control units may be insufficient
Solution Approach 1:
The module housing is segmented into functional zones: a protective membrane structure for mechanical load absorption, dedicated cable channels, and control unit mounting areas. This segmentation allows each component to be optimized for its specific function while maintaining overall compactness, enabling space-saving design without compromising protection or accommodating necessary auxiliary components.
3Stability of the object's composition
If the cell stack is enclosed in an inner housing or cage to reduce swelling, then the counterforce against swelling is improved, but external mechanical stresses are transferred to the cell stack via the housing or cage causing damage
Solution Approach 1:
A specialized membrane structure serves as an intermediary between the cell stack and the external environment. This membrane provides gentle, distributed support to counteract swelling while its flexible nature prevents concentration of mechanical stresses that could damage the cell stack. The membrane acts as a cushioning intermediary that decouples the cell stack from harsh external mechanical loads.
4Temperature
If a cooling plate is clamped to the cell pack by means of a spring device to ensure improved cooling, then the heat dissipation is improved, but the battery cells are only moderately protected from external mechanical influences
Solution Approach 1:
The cooling plate and protective membrane structure are merged into an integrated component that simultaneously provides thermal management and mechanical protection. The cooling plate is designed with flexible mounting that allows it to function as both a heat dissipation surface and part of the protective membrane system, achieving dual functionality without requiring separate spring devices or additional structural elements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved protection against external mechanical stresses, reduces swelling, and enhances heat dissipation, ensuring safer operation by converting kinetic energy into deformation energy and distributing forces to prevent cell pack damage, while maintaining a cost-effective and efficient design.
Implementation Method 1
the spring device is designed to press the cell pack in the direction of a second module side wall opposite the first module side wall to form a deformation space between the first module side wall and the cell pack
Implementation Method 2
A cooling device for dissipating heat from the cell pack is arranged between the cell pack and the module cover
Implementation Method 3
A cooling device for dissipating heat from the cell pack is arranged between the cell pack and the module cover
Implementation Method 4
ensuring improved protection of the cell pack against external mechanical stresses... by converting kinetic energy into deformation energy
Data Source
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AI summary
The invention relates to a load-bearing battery module (1) for a motor vehicle (2), comprising a module housing (3) with module side walls (4), a module base (5), and a module cover (6), and a cell pack (7) with several battery cells (8) arranged within the module housing (3). At least one spring device (9) is arranged between at least one first module side wall (4a) and the cell pack (7), the spring device (9) being designed to press the cell pack (7) towards a second module side wall (4b) opposite the first module side wall (4a) to form a deformation space (10) between the first module side wall and the cell pack. The invention further relates to a motor vehicle (2) with an electric motor (16) and a battery module (1) according to the invention.