Battery Module Insulating Plate with Obtuse Angles
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Solution Overview
Problem
The existing battery modules suffer from insulating plate damage and reduced energy density due to sharp-angled structures that occupy internal space, leading to instability and inefficiency in current flow.
Innovation Solution
A battery module design featuring an insulating plate with plate assemblies connected through a connecting plate, forming obtuse angles and guiding grooves that allow tabs to pass through securely, eliminating sharp edges and optimizing space for improved energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If sharp-angled structures are used in the insulating plate, then the structural simplicity is maintained, but the internal space is reduced and energy density is lowered
Solution Approach 1:
The insulating plate replaces sharp-angled structures with curved surfaces and rounded edges. The plate assembly features a curved top surface and rounded corners, eliminating sharp angles that would occupy internal space. This curvature design maintains structural integrity while maximizing the available internal space for battery units, thereby improving energy density without significantly increasing structural complexity.
2Quantity of substance
If obtuse angles are used in the insulating plate, then the internal space is increased and energy density is improved, but the manufacturing precision requirements are increased
Solution Approach 1:
The design specifies obtuse angles (greater than 90 degrees) for the plate assembly and connecting plates, which is a parameter change from conventional sharp angles. This angular parameter optimization increases internal space and improves energy density. The manufacturing precision requirement is managed by providing specific angle ranges rather than exact values, allowing for practical manufacturing tolerances while maintaining the beneficial geometric effects of obtuse angles.
3Manufacturing precision
If guiding grooves are added to the insulating plate, then the tab positioning accuracy is improved and current flow stability is enhanced, but the device complexity increases
Solution Approach 1:
Guiding grooves are added to the plate assembly to serve as intermediary structures that facilitate proper tab positioning. These grooves act as mechanical guides that constrain tab movement and ensure accurate alignment during assembly. The grooves are integrated into the curved surface design, so they follow the contour of the plate assembly, maintaining the overall aesthetic and structural integrity while providing the necessary positioning function.
4Strength
If connecting plates are used to join plate assemblies, then the structural integrity is improved and damage resistance is enhanced, but the occupied space increases and energy density is reduced
Solution Approach 1:
The insulating plate is segmented into multiple plate assemblies that are joined by connecting plates. This segmentation allows for a modular design where the connecting plates serve dual purposes: providing structural reinforcement and acting as spacers that maintain optimal spacing between plate assemblies. The connecting plates are designed with minimal thickness to reduce space occupation while maintaining sufficient structural integrity and damage resistance.
Data Source
AI summary
The present application relates to a battery module. The battery module includes a battery group and an insulating plate. The battery group includes a bus bar and a plurality of battery units, each battery unit includes a tab which includes a connecting segment and a bending segment. The insulating plate includes a plurality of plate assemblies, and the adjacent plate assemblies are connected through a connecting plate. There is an obtuse angle between each plate assembly and the connecting plate connected thereto. Each connecting segment passes through a guiding groove, and the bending segment and the bus bar are fixed and connected. The guiding groove can adjust the altitude of the tab as it passes through the insulating plate. The bending segment can be connected to the bus bar, then the process requirements can be met with a small space, which improves the energy density of the battery module.