Battery Module Flange Plates for Cell Stability and Heat Dissipation
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Solution Overview
Problem
Existing battery modules face challenges in preventing movement and heat dissipation of battery cells, particularly in high-capacity applications, and require materials that balance insulation and structural support while minimizing manufacturing costs.
Innovation Solution
The battery module design extends upper and lower plates to the sides to secure battery cells, incorporates insulating materials like ABS, PS, PP, or PE for the plates, and includes flange portions to prevent movement and dissipate heat, while using fastening members and ribs for structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are electrically connected to increase capacity and output, then the energy storage capability improves, but the movement and stability control of battery cells becomes more difficult
Solution Approach 1:
The top plate and bottom plate are extended to form flange portions that cover the side surfaces of the battery cells. This merging of structural elements creates a unified support system that stabilizes multiple battery cells simultaneously, preventing their movement while maintaining the increased capacity achieved through electrical connection.
Solution Approach 2:
The plates are extended from a simple top-bottom configuration to include lateral flange portions that wrap around the side surfaces of battery cells. This dimensional extension adds lateral constraint capability, preventing not only vertical but also horizontal movement of battery cells, thus comprehensively improving stability.
2Reliability
If insulating materials are used for plates, then electrical insulation performance improves, but structural support strength may be reduced
Solution Approach 1:
The plates are constructed as composite structures combining insulating materials (such as polymers like ABS, PS, PP, PI, or PE) with reinforcing elements (ribs and flange portions). This composite design provides both electrical insulation and mechanical strength, resolving the contradiction between insulation performance and structural support.
Solution Approach 2:
The plate structure is segmented into multiple functional portions: base portions for electrical insulation and support, and rib portions for mechanical reinforcement. This segmentation allows each portion to be optimized for its specific function while working together as an integrated structure.
3Stability of the object's composition
If flange portions are extended to cover side surfaces, then battery cell movement prevention improves, but manufacturing complexity increases
Solution Approach 1:
The support function and the positioning function are merged into a single integrated plate structure. The flange portions simultaneously provide structural support and lateral positioning constraints for battery cells, eliminating the need for separate positioning components and reducing overall device complexity.
Solution Approach 2:
The extended plates with flange portions serve multiple functions: electrical insulation, structural support, lateral positioning, and heat dissipation. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure despite the extended geometry.
4Reliability
If multiple plates and components are used for support and insulation, then reliability improves, but manufacturing cost increases
Solution Approach 1:
Multiple functions previously requiring separate components (insulation plates, support structures, positioning elements) are merged into integrated top and bottom plate assemblies with flange portions. This reduction in component count lowers manufacturing costs while maintaining comprehensive safety and stability functions.
Solution Approach 2:
The extended plates with flange portions serve multiple functions simultaneously: electrical insulation, structural support, positioning, and heat dissipation. This multi-functionality eliminates the need for multiple separate components, reducing assembly complexity and manufacturing cost while maintaining high reliability.
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 design effectively prevents cell movement, enhances insulation to prevent short circuits, and improves heat dissipation, reducing manufacturing costs and ensuring safety and efficiency in high-capacity battery applications.
Implementation Method 1
The top and bottom plates may be formed of a material having an insulation property. The top and bottom plates may include at least one selected from polymers
Implementation Method 2
a top flange portion covering at least a portion of the side surfaces of the battery cells; and a bottom flange portion covering at least a portion of the side surfaces of the battery cells
Data Source
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AI summary
A battery module includes a pair of end plates; a plurality of battery cells aligned with each other between the pair of the end plates, wherein each of the battery cells has a top surface, a bottom surface located substantially opposite to the top surface, and side surfaces extending between the top surface and the bottom surface; a top plate having a top base portion extending across the top surface of the battery cells and a top flange portion covering at least a portion of the side surfaces of the battery cells; and a bottom plate having a bottom base portion extending across the bottom surface of the battery cells and a bottom flange portion covering at least a portion of the side surfaces of the battery cells.