Battery Module Interlocking End Plate Side Plate Assembly
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Solution Overview
Problem
Current battery module assembly methods, such as bolt fixation, bandage fixation, and end plate-side plate welding, face issues with connection reliability, anti-impact strength, corrosion resistance, and high costs, leading to potential disassembly, short circuits, and safety risks due to inadequate fixation strength.
Innovation Solution
A battery module design featuring end plates with X-direction groove portions and side plates with inserting portions that interlock to provide a secure, integral connection, enhancing assembly accuracy and reliability while simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bolt fixation is used to connect end plates and side plates, then the connection can be easily assembled and disassembled, but the connection reliability deteriorates during continuous vibration as bolts easily loosen
Solution Approach 1:
The side plate is segmented into a body portion and inserting portions that extend from its ends. These inserting portions are inserted into groove portions formed on the end plates, creating a modular interlocking structure that prevents relative movement while maintaining assembly simplicity.
Solution Approach 2:
The inserting portions of the side plate are nested into the groove portions of the end plates. This nesting structure creates a secure interlocking connection where the inserting portions fit within the groove portions, preventing loosening during vibration while allowing straightforward assembly.
2Ease of manufacture
If bandage fixation is used to wrap around stacked batteries, then the assembly process is simple, but the anti-impact strength and corrosion resistance deteriorate
Solution Approach 1:
The side plate is divided into a body portion and inserting portions that extend from its ends. These inserting portions are inserted into groove portions on the end plates, creating a rigid interlocking structure that provides superior anti-impact strength compared to bandage fixation.
Solution Approach 2:
Instead of using a complete bandage wrap that requires full circumferential coverage, the inserting portions extend only partially from the side plate ends into the groove portions. This partial action achieves the necessary mechanical interlocking and structural strength without the complexity and material limitations of full bandage fixation.
3Strength
If end plate-side plate welding is used to connect plates, then the connection strength is high, but the manufacturing cost and scrapping rate increase while assembling efficiency decreases
Solution Approach 1:
The side plate is segmented into a body portion and inserting portions. This segmentation allows for simple mechanical insertion into groove portions on the end plates, eliminating the need for complex welding operations while maintaining high connection strength and improving assembling efficiency.
Solution Approach 2:
The inserting portions extend only partially from the side plate ends into the groove portions, providing sufficient mechanical interlocking and connection strength without requiring complete fusion or welding. This partial insertion approach achieves the necessary structural integrity while dramatically reducing manufacturing complexity and improving assembly speed.
Data Source
AI summary
The present disclosure provides a battery module, which comprises a battery group, two end plates and two side plates. Each end plate has X direction groove portions respectively formed to two ends of the end plate in the X direction. Each side plate has: a body portion positioned at one of the two ends of the battery group in the X direction; and inserting portions respectively extending from two ends of the body portion in the Y direction toward the X direction. The inserting portions of each side plate are respectively inserted into the corresponding X direction groove portions of the end plates to limit relative movement between each side plate and the end plates in the Y direction to make each side plate and the end plates fixed and connected. Strength of the battery module is improved and the possibility in connection failure of the battery module is reduced.