Extended Insulation Pad Layout for Battery Module Side Plate Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery modules with a 4-plate structure, the inclination of side plates during cell stack pressing can lead to positional changes of battery cells and bus bar frames, causing fatigue at welding portions and potential product failure.
Innovation Solution
A battery module design featuring an insulation pad with an extended length, interposed between the cell stack and side plates, and between bus bar frames and side plates, to prevent side plate inclination and ensure horizontal pressing of the cell stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation pad is inserted between the cell stack and side plate to prevent inclination, then the side plate inclination is reduced, but the insulation pad cannot perfectly prevent tilting due to gaps created by design tolerance between the bus bar frame and side plate
Solution Approach 1:
The insulation pad is extended from a single-dimensional placement between the cell stack and side plate to a multi-dimensional configuration that also fills the gap between the bus bar frame and side plate. This extended placement in multiple spatial dimensions ensures comprehensive coverage and eliminates the tilting issue that occurred with the original single-location insulation pad.
Solution Approach 2:
The extended insulation pad acts as an intermediary element that fills the gap between the bus bar frame and side plate, preventing direct contact and the resulting inclination. By positioning the insulation pad at multiple locations (between cell stack-side plate and between bus bar frame-side plate), it mediates the mechanical interaction and maintains proper alignment.
2Force
If the side plate is pressed in an inclined state, then the cell stack is compressed, but the position of each battery cell and bus bar frame changes from its initial design, causing welding portion fatigue
Solution Approach 1:
The extended insulation pad is pre-positioned to counteract the potential inclination of the side plate before compression occurs. By filling the gap between the bus bar frame and side plate in advance, the insulation pad prevents the side plate from tilting during the compression process, thereby preventing the harmful inclined pressing that would cause welding portion fatigue.
3Reliability
If a 4-plate structure with resin bus bar frame is used, then the bus bar frame prevents side plate inclination to some extent, but gaps between bus bar frame and side plate due to design tolerance allow tilting to occur
Solution Approach 1:
The extended insulation pad replicates the protective function at multiple locations. By placing insulation pads at both the cell stack-side plate interface and the bus bar frame-side plate interface, the solution copies the insulation function to ensure comprehensive prevention of side plate inclination without requiring a completely new structural design.
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 extended insulation pad effectively prevents side plate inclination, maintaining the original positional relationship of battery cells and bus bar frames, thereby reducing fatigue at welding portions and preventing product failure.
Implementation Method 1
an insulation pad 4 made of a material with elasticity is inserted between the cell stack and the side plate 3
Data Source
AI summary
A battery module includes a cell stack in which a plurality of battery cells are stacked; a pair of bus bar frames configured to cover one side and another side, respectively, of the cell stack in a longitudinal direction; a housing configured to accommodate a combined body of the cell stack and the pair of bus bar frames so that the pair of bus bar frames is exposed to an outside of the housing; and an insulation pad interposed between a side surface of the cell stack and an inner surface of the housing and between a side surface of one of the pair of bus bar frames and the inner surface of the housing.