Battery Module Insulating Rod Force Distribution
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Solution Overview
Problem
Existing battery modules face challenges in maintaining long-term reliability of connections between battery cells due to misalignment and stress on connections, leading to increased contact resistance and potential short circuits.
Innovation Solution
A battery module design featuring a stacked structure with insulating rod members and tightening members that ensure close contact between conductive members, using metallic rods coated with insulating layers to reduce stress and improve surface contact stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixing methods are used to secure battery cells, then vibration and impact are addressed, but stress on terminals increases leading to reduced reliability and durability
Solution Approach 1:
An insulating rod member is introduced as an intermediary component between the tightening member and the battery units. This rod member distributes the tightening force across multiple battery units simultaneously, preventing concentrated stress on individual terminals while maintaining secure connections. The rod member acts as a force-distributing mediator that resolves the contradiction between reliable fixation and terminal protection.
2Reliability
If battery units are tightly fastened to ensure electrical connection, then contact resistance decreases, but misalignment and stress on connections increase
Solution Approach 1:
The insulating rod member serves multiple functions simultaneously: it provides mechanical support for tightening, distributes force across multiple units, maintains insulation between adjacent battery units, and accommodates minor misalignments. This multi-functional component enables reliable connections without requiring high manufacturing precision for alignment.
3Reliability
If conductive members are used for electrical connection, then electrical conductivity is achieved, but risk of short circuits between adjacent units increases
Solution Approach 1:
The insulating rod member serves as an intermediary barrier between adjacent battery units, physically separating them while allowing mechanical tightening. This insulating mediator prevents direct electrical contact between adjacent units, eliminating short circuit risk while maintaining the necessary mechanical connection for electrical conductivity through designated pathways.
4Reliability
If multiple components are used for fixing and connecting battery units, then connection reliability improves, but device complexity increases
Solution Approach 1:
The insulating rod member is designed as a single multi-functional component that combines mechanical support, force distribution, electrical insulation, and alignment tolerance in one element. This universal component reduces overall structure complexity compared to using separate components for each function, while maintaining high connection reliability.
Data Source
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AI summary
A battery module includes a stacked structure including: at least a plurality of stacked battery units; an insulating rod member passing through the stacked structure; and a tightening member that tightens the stacked structure from both ends of the insulating rod member passing through the stacked structure. The tightening member tightens the stacked structure to fasten the battery units, so that the close contact portions of the conductive members of adjacent ones of the battery units are brought in close contact with each other and the adjacent battery units are electrically connected with each other.