Battery Module Fixation Using 2-Component Curing Material
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Solution Overview
Problem
Existing battery module fixation methods in energy storage systems, such as those in electric vehicles, face challenges in securely and reliably stabilizing battery modules within compartments, particularly under various operational conditions like vibrations and thermal changes.
Innovation Solution
A fixation arrangement using a cartridge-based system with a 2-component curing material and a foam material, where the curing material is activated by a fixation pin rupturing a dividing wall, providing a stable and flexible interface between the battery module and the compartment, and a foam material for additional cushioning and tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid fixation method is used to secure battery modules, then stability against external forces is improved, but the ability to accommodate thermal expansion and relative movement is worsened
Solution Approach 1:
The patent employs a composite fixation system combining rigid elements (fixation pins, battery module housing) with flexible elements (foam material, curing material). The foam material provides initial cushioning and tolerance compensation, while the curing material transforms from liquid to solid state to create a bonded connection that accommodates thermal expansion while maintaining fixation strength.
Solution Approach 2:
The curing material undergoes a parameter change from liquid to solid state through curing, transforming the fixation system from flexible to rigid-bonded. This parameter change allows the system to achieve both initial flexibility for tolerance compensation and final strength for stable fixation.
2Reliability
If a 2-component curing material system is used, then fixation reliability is improved, but device complexity is worsened
Solution Approach 1:
The curing material is segmented into two separate components stored in distinct chambers, preventing premature mixing. This segmentation allows each component to be optimized independently while maintaining reliability through controlled mixing only when needed during the fixation process.
Solution Approach 2:
A dividing wall acts as an intermediary barrier between the two curing material components, preventing their mixing during storage and application. This intermediary structure ensures the components remain separate until the intended moment of mixing, simplifying the overall system by providing a clear separation mechanism.
3Adaptability or versatility
If foam material is used for cushioning, then tolerance compensation is improved, but fixation strength is worsened
Solution Approach 1:
The foam material performs preliminary cushioning and tolerance compensation before the curing material sets. This preliminary action protects the battery module during insertion and positioning, while the subsequent curing process provides the final strong bonded fixation.
Solution Approach 2:
The foam material provides beforehand cushioning between the battery module and the fixation pins, absorbing initial impacts and accommodating dimensional tolerances. This prior cushioning prevents damage during assembly while the curing material subsequently provides strong permanent fixation.
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
This solution effectively secures battery modules, providing stability against external forces and thermal changes while allowing for relative movement, thus enhancing the reliability and durability of the energy storage system.
Implementation Method 1
a first curing material component section including a first curing component of a 2-component curing material, a second curing material component section including a second curing component of the 2-component curing material
Implementation Method 2
a foam material section containing a foam material
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
In an embodiment, a battery module fixation arrangement includes gaps arranged between fixation recesses and fixation pins. Upon insertion of a battery module into a battery module compartment, each gap is at least partially filled with a curing material that cures after the insertion. In a further embodiment, the fixation recesses may include cartridges that comprise a foam material along with multiple components that mix to form the curing material after the insertion.