Battery Module End Plate Coupling and Insulation
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Solution Overview
Problem
Existing battery modules lack a standardized mechanism for secure coupling and risk of short circuits between electrodes and adjacent wires, which complicates the connection and operation of multiple battery cells in series or parallel configurations.
Innovation Solution
The introduction of an end plate with specific coupling units, alignment protrusions, and insulating features that facilitate secure coupling of battery modules while preventing short circuits through integrated stud bolts and wire accommodation units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery modules are coupled using conventional methods, then connection is possible, but coupling security and alignment precision are insufficient
Solution Approach 1:
The coupling mechanism is divided into separate functional elements: alignment protrusions on one end plate and corresponding alignment grooves on the adjacent end plate. This segmentation allows each component to perform its specific function independently, ensuring both alignment precision and coupling security without requiring high manufacturing precision across the entire assembly.
Solution Approach 2:
Alignment protrusions and grooves act as intermediary elements between the two end plates. These intermediaries guide the coupling process, ensuring proper alignment before final connection is made, thereby improving both alignment precision and coupling reliability without demanding high manufacturing tolerances on the main coupling surfaces.
2Volume of moving object
If battery modules are coupled in close proximity, then space efficiency increases, but risk of short circuit between electrode and wire increases
Solution Approach 1:
The insulating wall acts as an intermediary barrier between the electrode and the wire. This intermediate insulating structure prevents direct contact between conductive elements while allowing the battery modules to be coupled in close proximity, thus maintaining space efficiency while eliminating short circuit risk.
Solution Approach 2:
The harmful factor (short circuit risk) is extracted and isolated by introducing a dedicated insulating wall structure. This separate insulating element specifically addresses the short circuit prevention need without interfering with the coupling mechanism or space utilization, allowing tight packaging while maintaining electrical safety.
3Quantity of substance
If multiple battery cells are stacked to increase capacity, then output and capacity increase, but structural stability and coupling reliability decrease
Solution Approach 1:
The multi-cell battery stack is segmented into modular units, each terminated with standardized end plates containing coupling mechanisms. This segmentation allows multiple battery modules to be stacked vertically while maintaining structural stability through repeated, consistent coupling interfaces, preventing accumulation of alignment errors and maintaining overall stack integrity.
Solution Approach 2:
The end plate design provides universal coupling functionality that works consistently across all battery modules in the stack. The standardized alignment protrusions, grooves, and coupling holes create a repeatable interface that maintains structural stability regardless of the number of modules stacked, enabling scalable capacity increase without compromising reliability.
Data Source
AI summary
A battery module includes a battery array and an end plate. The battery array includes at least two battery cells that are stacked, the battery cells including a terminal surface where an electrode and a vent are exposed and an opposite bottom side. The end plate is disposed at the terminal surface of the stacked battery cells and includes an electrode hole through which the electrode is exposed. a first coupling unit including an alignment protrusion is disposed on one side of the end plate, and a second coupling unit including an accommodation unit is disposed on an opposite side of the end plate. The accommodation unit of the second coupling unit is configured to be coupled with an alignment protrusion of a first coupling unit of an end plate of an adjacent battery module.