Battery Module Frame System with Folded Tabs
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Solution Overview
Problem
Existing battery modules face issues with cell bulge expansion due to state of charge, temperature, and aging, leading to increased installation space requirements and reduced performance and service life, and existing frame systems are prone to shearing forces and structural integrity loss under external forces.
Innovation Solution
A quadrangular frame system with pressure plates and side parts where tabs are folded to engage behind the pressure plates, distributing tensile loads and reducing shearing forces, and additional fastening elements ensure secure attachment and increased rigidity, while identical design components reduce manufacturing costs and enhance assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If strip-like connecting elements with perpendicular holes are used to attach side parts to pressure plates, then the frame structure is formed, but shearing forces at the connection points can destroy the connection
Solution Approach 1:
The patent inverts the traditional attachment approach by having tabs extend perpendicular to the pressure plates and engage from the sides rather than using perpendicular holes. The tabs engage behind the pressure plates in a form-fitting manner, converting shear loads into tensile loads on the tabs, which significantly increases connection strength and reliability.
Solution Approach 2:
The attachment mechanism transitions from a two-dimensional perpendicular hole connection to a three-dimensional form-fitting engagement where tabs wrap around and engage behind the pressure plates. This dimensional change allows the connection to resist forces more effectively by distributing loads across multiple engagement points.
2Stability of the object's composition
If multiple strip-like connecting elements are used to connect end plates, then the frame structure is formed, but the frame can twist under external forces losing structural integrity
Solution Approach 1:
The tabs are designed to engage behind the pressure plates in advance, creating a pre-loaded form-fitting connection that prevents frame twisting before external forces are applied. This preliminary engagement ensures structural integrity is maintained from the outset.
Solution Approach 2:
The tabs are inserted into and engage behind the pressure plates, creating a nested connection where the side parts are effectively nested within the frame structure. This nested arrangement prevents twisting by locking the components in place against external forces.
3Strength
If tabs are folded to engage behind pressure plates in form-fitting manner, then tensile loads are distributed and shearing forces reduced, but manufacturing complexity increases
Solution Approach 1:
The tabs are formed as an integrated part of the side parts through deformation, merging the attachment feature with the main component. This eliminates the need for separate fasteners or complex assembly steps, reducing manufacturing complexity while maintaining superior load distribution capabilities.
Solution Approach 2:
The side parts are deformed to create the tabs, changing the physical state and shape of the material from flat to three-dimensional. This parameter change enables the form-fitting engagement behind the pressure plates, achieving excellent load distribution through a relatively simple manufacturing process.
Data Source
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AI summary
The invention relates to a rectangular rack system for accommodating at least one battery cell and a battery module with a rectangular rack system, wherein the rectangular rack system is characterized by good force transmission, inexpensive production and simple fitting.