Composite End Plate Battery Module for Rigidity and Weight Balance
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Solution Overview
Problem
Battery modules require increased rigidity to manage higher voltage outputs without corresponding increases in size and weight, which is challenging due to the limitations of welded structures using traditional materials for end plates and fastening members.
Innovation Solution
A battery module design incorporating end plates with a first metal portion for high Young's modulus and a second metal portion for low density, combined with restraint members made of high Young's modulus metal, and welded connections to enhance rigidity while minimizing size and weight increments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of batteries in the battery module is increased to output higher voltage, then the power output is improved, but the dimensional variation increases due to swollen batteries
Solution Approach 1:
The end plate is segmented into multiple portions with different materials: a first portion made of a first metal and a second portion made of a second metal. This segmentation allows different regions of the end plate to serve different functions - one region provides rigidity while another provides light weight, resolving the contradiction between power output and dimensional variation
Solution Approach 2:
The end plate uses composite materials by combining a first metal and a second metal in different portions. This composite structure enables the end plate to simultaneously achieve high rigidity (from the first metal) and low weight (from the second metal), thereby controlling dimensional variation while supporting higher voltage output from increased battery count
2Manufacturing precision
If the rigidity of the battery module is increased to reduce dimensional variation, then the dimensional accuracy is improved, but the size and weight of the battery module increase
Solution Approach 1:
Different portions of the end plate have different material qualities: the first portion is made of a first metal with specific properties while the second portion is made of a second metal with different properties. This local quality differentiation allows the end plate to provide rigidity only where needed while maintaining light weight in other areas, thus improving dimensional accuracy without increasing overall weight
Solution Approach 2:
The end plate employs composite materials combining a first metal and a second metal in different portions. This composite construction achieves the necessary rigidity for dimensional accuracy while the lightweight second metal portion prevents overall weight increase, resolving the contradiction between dimensional accuracy and weight
3Strength
If the rigidity of the battery module is increased by using welded structure with end plates and fastening member, then the structural strength is improved, but the material selection is restricted
Solution Approach 1:
The end plate is divided into a first portion and a second portion made of different metals. This segmentation allows each portion to be made of materials optimized for its specific function, thereby maintaining material selection flexibility while achieving the structural strength needed for rigid welded connections
Solution Approach 2:
The end plate uses composite materials of a first metal and a second metal in different portions. This composite approach enables selection of materials with appropriate properties for each region, maintaining adaptability in material selection while achieving the structural strength required for rigid welded connections to the restraint member
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 design effectively increases the rigidity of the battery module, reduces dimensional variation, and maintains a compact size and weight, enhancing energy density and dimensional accuracy.
Implementation Method 1
a welded portion that connects the first portion of the at least one end plate with the restraint member
Data Source
AI summary
A battery module includes: a battery stack that includes a plurality of batteries stacked; a pair of end plates that are disposed at both ends, in stack direction X in which the batteries are stacked, of the battery stack, the pair of end plates including at least one end plate that includes a first portion made of a first metal that has a Young's modulus higher than a Young's modulus of a second metal, and a second portion made of the second metal that has a density lower than a density of the first metal; a restraint member that is made of the first metal and sandwiches the battery stack and the pair of end plates in stack direction X; and a welded portion that connects the first portion of the at least one end plate with the restraint member.