Battery Module End Plate Fixing Band Thermal Expansion
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Solution Overview
Problem
The existing battery modules for electric vehicles face challenges due to the expansion of lithium ion batteries, which causes distortion and increased electrical resistance, and the use of bolts and nuts for fixing end plates results in a bulky design, limiting installation space and design flexibility.
Innovation Solution
A battery module with a fixing band made of materials that expand when heated and contract when cooled, such as aluminum-coated steel, which encircles the end plates and battery unit, eliminating the need for bolts and nuts by using fasteners like welds, turnbuckles, or clips to form a closed loop, thereby securing the end plates and reducing volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts and nuts are used to connect connection rods and end plates, then the connection is strong and reliable, but the assembly time increases and the volume of the battery module increases due to protruding components
Solution Approach 1:
The invention extracts and eliminates the bolts and nuts from the connection system. Instead of using traditional threaded fasteners, the patent employs a press-fit connection rod that directly engages with the end plate through interference fitting, removing the need for separate fastening components and significantly reducing assembly time while maintaining connection strength
Solution Approach 2:
The invention replaces the mechanical threaded fastening system with a press-fit interference connection system. The connection rod is designed with dimensions that create interference fit with the end plate hole, generating frictional force and mechanical interlocking that provides strong connection without requiring bolts, nuts, or threading operations
2Strength
If bolts and nuts are used to connect connection rods and end plates, then the connection is secure, but the volume of the battery module increases due to protruding fasteners
Solution Approach 1:
The invention removes the protruding bolts and nuts from the assembly, eliminating the volume they occupy outside the battery module envelope. The press-fit connection rod is contained within the battery module structure, with no external protrusions, thereby reducing the overall volume while maintaining secure connection through interference fit
Solution Approach 2:
Instead of using external fasteners that protrude outward to secure the connection, the invention inverts the approach by using an internal press-fit mechanism where the connection rod itself, through dimensional interference, creates the securing force from within the structure, eliminating external volume increase
3Reliability
If multiple bolts and nuts are used for fixing end plates, then the fixation is reliable, but the structure becomes complex and the assembly process becomes cumbersome
Solution Approach 1:
The invention extracts multiple bolts and nuts from the fixation system and replaces them with a single press-fit connection rod. This single component performs the fixation function that previously required multiple fasteners, significantly simplifying the structure while maintaining reliable fixation through interference fit and mechanical interlocking
Solution Approach 2:
The invention merges the functions of multiple bolts and nuts into a single integrated press-fit connection rod. The connection rod combines the positioning, securing, and structural support functions that were previously distributed across multiple fastening components, reducing structural complexity while ensuring reliable end plate 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
The solution provides a simpler assembly process, minimizes protrusion of connection components, and maintains a strong clamping force, reducing the overall volume of the battery module and enhancing design flexibility, especially in space-constrained electric vehicles.
Implementation Method 1
the fixing band is made from a material that expands when heated and contracts when cooled
Implementation Method 2
the fixing band is made from a material that expands when heated and contracts when cooled
Data Source
AI summary
A battery module includes a battery unit having a plurality of batteries; a pair of end plates, one of the end plates installed at either end of the battery unit; and a fixing band that encircles the end plates and the battery unit, wherein the fixing band is made from a material that expands when heated and contracts when cooled.