Battery Module End Blocks for Uniform Pressure Distribution
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Solution Overview
Problem
Existing battery modules face challenges in providing sufficient power and capacity for high-power applications like electric vehicles, as they often require multiple battery cells connected in series, which can lead to structural limitations and swelling issues due to inadequate pressure distribution.
Innovation Solution
A battery module design featuring end blocks with power terminal portions made of insulating material and embedded conductive metal, which are electrically connected to the battery cells and include protruding regions for enhanced pressure and structural integrity, allowing for stronger pressing of battery cells and improved connection between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are connected in series to increase power and capacity, then the output voltage and power increase, but structural limitations and swelling issues occur due to inadequate pressure distribution
Solution Approach 1:
The battery module is divided into multiple battery cells connected in series, with each cell independently managed. The end blocks are segmented to provide individual pressing forces to adjacent battery cells, ensuring uniform pressure distribution across the entire module while maintaining high power output through series connection.
Solution Approach 2:
End blocks are introduced as intermediary components between the battery cells and the external environment. These end blocks transmit and distribute pressing forces uniformly to the battery cells, preventing direct contact issues and ensuring stable pressure distribution that prevents swelling while maintaining structural integrity for high power applications.
2Ease of manufacture
If traditional battery module configurations are used, then manufacturing is simpler, but swelling issues occur due to inadequate pressure distribution
Solution Approach 1:
The end blocks are pre-configured with pressing surfaces and structural features that apply uniform pressure to the battery cells before the module is fully assembled and sealed. This preliminary pressure application prevents swelling from occurring during operation, while the modular design maintains manufacturing simplicity through standardized components and assembly procedures.
3Object-affected harmful factors
If battery cells are pressed stronger to prevent swelling, then swelling is reduced, but connection reliability may be compromised without proper structural support
Solution Approach 1:
The end blocks are constructed using composite material structures that combine high compressive strength for pressing battery cells with high tensile strength for maintaining connection reliability. This composite structure allows the end blocks to simultaneously apply strong pressing forces to prevent swelling while maintaining structural integrity and reliable electrical connections under operational stresses.
Data Source
AI summary
A battery module includes a first battery cell, the first battery cell having a first electrode terminal and a second electrode terminal, a first end block adjacent to the first battery cell, the first end block having a first power terminal portion, and a connection portion electrically connecting the first electrode terminal to the first power terminal portion.