Battery Module Restraint via Interference Fit

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Solution Overview

Problem

Battery modules for vehicles using stainless steel endplates and sideplates are costly, massive, and non-serviceable, with difficult quality inspection of laser welds.

Innovation Solution

The use of high-strength steel endplates and plastic sideplates with snap features, eliminating the need for fasteners or mechanical joining, reduces cost and mass by 40% and simplifies assembly compared to laser welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If stainless steel endplates and sideplates are laser welded together, then structural integrity is achieved, but cost and mass increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidmodule mass

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The module structure is segmented into stainless steel endplates and aluminum sideplates, allowing each component to be optimized for its specific function. The endplates provide structural strength while the aluminum sideplates reduce overall mass, eliminating the need for entire modules to be made from heavy stainless steel.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a composite construction using dissimilar metals - stainless steel endplates combined with aluminum sideplates. This composite approach leverages the high strength of stainless steel where needed while utilizing the lightweight properties of aluminum for the sideplates, achieving optimal strength-to-weight ratio.

Inventive Principle:

Principle #40Composite materials

2Strength

If stainless steel endplates and sideplates are laser welded together, then structural integrity is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the complex laser welding process with a simpler mechanical attachment system. The aluminum sideplates are attached to stainless steel endplates through mechanical means such as rivets, bolts, or interlocking features, eliminating the need for expensive laser welding equipment and skilled welders while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If laser welding is used to join endplates and sideplates, then structural integrity is achieved, but quality inspection becomes difficult without destructive testing

Engineering Contradiction:

Improveweld qualityVSAvoidinspection accessibility

Core Design Contradiction:

StrengthVSDifficulty of detecting and measuring

Solution Approach 1:

By replacing laser welding with mechanical attachment methods, the patent enables non-destructive inspection of joint quality. Mechanical joints can be visually inspected, measured with calipers, or tested non-destructively, whereas laser welds require destructive sampling to verify quality, thus improving inspection accessibility and reducing quality risks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If stainless steel endplates and sideplates are used, then structural integrity is maintained, but serviceability is lost

Engineering Contradiction:

Improvestructural integrityVSAvoidmodule serviceability

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The modular segmented design with dissimilar metal endplates and sideplates allows for easy disassembly and reassembly. If a sideplate is damaged, it can be independently removed and replaced without affecting the endplates or other components, significantly improving serviceability compared to a monolithic welded structure.

Inventive Principle:

Principle #1Segmentation

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

The solution provides a cost-effective, lighter battery module with improved assembly efficiency and quality inspection, while maintaining structural integrity through compression and frictional forces, and allowing for easier expansion and maintenance.

Implementation Method 1

The sideplates include a first mating portion and the endplates include a second mating portion that engages the first mating portion to provide an interference fit. The interference fit joins the sideplates and the endplates together and bands the plurality of cells together between the sideplates and the endplates.

Methodology Applied

Scientific EffectInterference fit: Friction

Data Source

PatentUS9362536B2Optimized module restraint system

Publication Date: 2016.06.07 SAMSUNG SDI CO LTD

AI summary

A battery module according to the principles of the present disclosure includes a plurality of battery cells, a pair of sideplates, and a pair of endplates. The sideplates are disposed on opposite sides of the plurality of battery cells and the endplates are disposed at opposite ends of the battery module. The sideplates include a first mating portion and the endplates include a second mating portion that engages the first mating portion to provide an interference fit. The interference fit joins the sideplates and the endplates together and bands the plurality of cells together between the sideplates and the endplates.