Battery Module Insulation Fixing Structure for Cell Stability
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Solution Overview
Problem
Battery modules used without static positioning experience shaking, leading to issues such as short circuits and damage to wiring harnesses due to collisions and friction with cell housings, which can result in thermal runaway.
Innovation Solution
A battery module design incorporating a cell assembly, a first component, a second component, and an insulation member, where the first component is fixed to the housing via the insulation member, and the second component provides an accommodating space with features like recesses and protrusions to stabilize the cell assembly and reduce friction and collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cells are accommodated inside the housing without additional fixing structures, then the device complexity is reduced, but the cells shake during use without static positioning, leading to short circuits and damage to wiring harnesses
Solution Approach 1:
The patent divides the fixing function into multiple segments: the first component (fixing component) with fixing portions, the second component (support component) with supporting portions, and insulation members. This segmented approach distributes the stabilization function across multiple specialized elements rather than using a single complex structure, thereby improving cell stability while keeping each individual component relatively simple.
Solution Approach 2:
The patent introduces intermediary elements between the cells and the housing: the first component acts as an intermediary fixing mechanism, the second component serves as an intermediary support structure, and insulation members mediate between the cells and surrounding components. These intermediaries prevent direct contact and shaking between cells and housing, improving reliability without requiring direct integration.
2Reliability
If the first component is fixed to the housing using traditional fixing methods, then the stability of the first component is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the fixing function into the structural design of the first and second components themselves. The fixing portions and supporting portions are integrated into the components' geometries, allowing them to be fixed to each other and to the housing through their inherent structural features rather than requiring separate fixing operations. This combining of structure and function simplifies the manufacturing process while maintaining stability.
Solution Approach 2:
Instead of adding fixing structures to secure the first component, the patent inverts the approach by designing the first component with fixing portions that naturally engage with corresponding features on the second component and housing. The components are designed to interlock or mate through their geometries, reversing the traditional approach of adding external fixing mechanisms.
3Reliability
If the second component provides comprehensive support for the cell assembly, then the stability and protection of cells is improved, but the energy density of the battery module decreases due to increased space occupation by support structures
Solution Approach 1:
The patent applies local quality by providing support and protection only where needed rather than uniformly throughout the housing. The second component has supporting portions strategically positioned to stabilize specific cells or groups of cells, and the first component provides localized fixing at critical connection points. This localized approach ensures protection while minimizing the overall space occupied by support structures, preserving energy density.
Solution Approach 2:
The patent implements partial action by providing just enough support and fixing functionality to prevent shaking and damage without over-engineering the support structures. The fixing portions and supporting portions are designed to provide sufficient stabilization for normal operation without excessive material or space consumption, achieving the minimum necessary protection while maximizing energy density.
4Reliability
If insulation members are used to bond and fix the first and second components, then the stability and sealing performance are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent changes the bonding parameters by using insulation members with specific material properties that provide both mechanical bonding strength and sealing functionality. The insulation members are designed with appropriate hardness, adhesion characteristics, and compressibility to ensure reliable bonding between the first and second components while accommodating reasonable variations in assembly alignment, thereby reducing the stringency of manufacturing precision requirements.
Data Source
AI summary
A battery module includes a cell assembly, a first component, a second component, and an insulation member. The cell assembly includes a plurality of cells, and each cell includes a cell housing and an electrode terminal, the electrode terminal extending out of the cell housing. Along a first direction, the first component is disposed on a side of the cell assembly, the electrode terminal is connected to the first component. The second component includes a base portion and an extension portion, where the base portion has an accommodating space, the first component is located in the accommodating space, and the extension portion protrudes from the base portion. At least a part of the insulation member is located in the accommodating space, and the first component and the second component are bonded and fixed through the insulation member.