Battery Module Perimeter Housing and Compression Plates
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Solution Overview
Problem
Existing battery modules for electric vehicles face challenges with high manufacturing costs, weight, long recharge times, and short service life, primarily due to inefficient assembly methods and lack of effective deformation management of battery cells.
Innovation Solution
A battery module design featuring a casing with expandable elements and compression plates that retain and compress battery cells using a perimeter housing, allowing for quick assembly and preventing cell collapse during maintenance or replacement, utilizing lightweight and fire-resistant materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are stacked without compression plates or perimeter housing, then assembly is simpler, but cells collapse during maintenance or replacement
Solution Approach 1:
The battery module is divided into functional components: perimeter housing for structural support, compression plates for cell retention, and modular cell stacks. This segmentation allows each component to perform its specific function while maintaining overall system reliability and ease of assembly.
Solution Approach 2:
The perimeter housing and compression plates are pre-assembled to form a rigid framework before cells are installed. This preliminary structural preparation ensures cells are immediately retained and compressed upon installation, preventing collapse during maintenance without complicating the overall assembly process.
2Strength
If welding is used to attach covers to form the casing, then structural strength is improved, but manufacturing cost and complexity increase
Solution Approach 1:
Clips serve as intermediary components that mechanically interlock the front cover, rear cover, and side bands to form the perimeter housing. This clipping mechanism provides sufficient structural strength while avoiding the high costs and complexity of welding operations.
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical system) with a clipping mechanism (purely mechanical system). The clips provide reliable structural attachment through mechanical interlocking, eliminating the need for expensive welding equipment and processes while maintaining adequate structural strength.
3Reliability
If expandable elements are intercalated between cells, then cell deformation is managed, but device complexity increases
Solution Approach 1:
Expandable elements are positioned between battery cells to automatically compensate for cell swelling or shrinking during operation. These elements self-adjust their expansion or contraction based on cell volume changes, managing deformation without requiring external control systems or complex mechanisms.
4Productivity
If cells are retained without a perimeter housing, then assembly is faster, but cells collapse when accessing the inside of the casing
Solution Approach 1:
The perimeter housing combines the functions of structural support, cell retention, and maintenance protection into a single integrated component. By merging these functions, the housing enables fast assembly while simultaneously preventing cell collapse during maintenance operations, as the rigid perimeter structure provides continuous support.
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 design facilitates efficient assembly, maintains cell dimensions, and ensures safe operation by preventing cell deformation, thereby enhancing the reliability and longevity of the battery module.
Implementation Method 1
a plurality of expandable elements intercalated between the battery cells
Implementation Method 2
two lateral compression plates covering a corresponding end of the set of cells according to a second direction perpendicular to the first direction, with the set of cells being arranged sandwiched between the compression plates
Data Source
Figure 1
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AI summary
Battery module (100) for an electric vehicle which comprises a set of cells comprising a plurality of battery cells stacked according to a first direction, and a plurality of expandable elements intercalated between the battery cells. The module also comprises a casing (4) which houses therein the set of cells. The casing (4) comprises a front cover (5) and a rear cover (6) such that each cover (5, 6) covers a corresponding end of the set of cells along the first direction. The front cover (5) and the rear cover (6) are attached by side bands (7), said side bands (7) being arranged according to a second direction perpendicular to the first direction, such that the front cover (5), the rear cover (6), and the side bands (7) form a perimeter housing in which the set of cells is compressed.