Battery Module End Plate with Thinned Sections and Strengthened Portions
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Solution Overview
Problem
Existing battery module end plates with uniform thickness are inefficient in distributing expansion forces during charging and discharging, leading to excessive weight and potential damage due to uneven force distribution, and are prone to deformation or breakage at thinner sections.
Innovation Solution
Designing end plates with a thicker middle section and thinner sections on the sides, where the thinned sections have strengthened portions protruding from the outer surface to enhance bending resistance, reducing overall weight while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end plate has uniform thickness, then the structural strength is sufficient to withstand expansion force, but the weight of the end plate and battery module increases
Solution Approach 1:
The end plate employs non-uniform thickness distribution with a thicker middle section and thinner side sections. The middle section has sufficient thickness to withstand the maximum expansion force from the battery group, while the side sections have reduced thickness to decrease weight. This local quality variation optimizes the balance between strength and weight by matching material distribution to the actual stress distribution pattern.
2Weight of stationary object
If the thinned section has reduced thickness to reduce weight, then the weight decreases, but the bending resistance and structural integrity deteriorate
Solution Approach 1:
Reinforcing ribs are introduced as intermediary structural elements within the thinned sections. These ribs act as mediators that provide additional bending resistance and structural support to the thinner plate regions without requiring increased overall thickness. The ribs distribute and reinforce the thinned sections, enabling weight reduction while maintaining adequate strength and structural integrity.
3Ease of manufacture
If the end plate has uniform thickness, then the manufacturing process is simple, but the force distribution efficiency is poor and material is wasted
Solution Approach 1:
The end plate design implements local quality variation through non-uniform thickness distribution. The middle section maintains greater thickness to handle the concentrated expansion forces from the battery group, while the side sections have reduced thickness where forces are smaller. This localized differentiation eliminates material waste by placing material only where structurally necessary, improving force distribution efficiency while remaining manufacturable.
4Ease of manufacture
If the thinned section lacks strengthened portions, then the manufacturing process is simpler, but the bending resistance is insufficient and deformation occurs
Solution Approach 1:
Reinforcing ribs are incorporated as intermediary elements within the thinned sections to provide the necessary bending resistance. These ribs are integrated into the plate structure during manufacturing, offering structural reinforcement without significantly complicating the manufacturing process. The ribs prevent deformation in the thinned sections while maintaining manufacturing feasibility.
Data Source
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AI summary
A battery module is provided, including: a battery group, including a plurality of batteries that is stacked; two end plates, respectively disposed at two ends of the battery group along a direction in which the plurality of batteries is stacked; and a connecting member, connecting the two end plates. Each of the two end plates has a middle section and thinned sections respectively located at two sides of the middle section in a length direction Y. A thickness of each of the thinned sections is smaller than a thickness of the middle section. Each of the thinned sections is provided with at least one strengthened portion protruding from an outer side surface of the thinned section. In the present disclosure, an overall weight of the battery module can be reduced when the thinned section has a smaller thickness than the middle section.