Battery Module Cushioning for Uniform Cell Surface Pressure
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Solution Overview
Problem
Existing battery modules experience non-uniform surface pressure distribution due to the expansion of battery cells during charging, leading to inefficiencies in energy distribution.
Innovation Solution
Incorporation of a cushioning material with corrugated plate springs and a soft resin having a hardness of E40 or less or E60 or more, which is applied on the battery cell surfaces, to uniformly distribute pressure by interposing the soft resin between the battery cells and the cushioning material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a restriction unit with flat plates is used to bind battery cells, then the battery cells are constrained during expansion, but the surface pressure distribution becomes non-uniform reducing energy efficiency
Solution Approach 1:
The invention replaces flat plates with corrugated plates having a wave-like curvature profile. This curvature allows the plates to conform to the expanding battery cell surfaces, distributing pressure uniformly across the contact areas while maintaining effective constraint during charging expansion.
Solution Approach 2:
The invention changes the geometric parameters of the constraint structure by introducing corrugation with specific wave patterns. The corrugated profile modifies how force is distributed during compression, transforming the pressure distribution from concentrated points to uniform surfaces, thereby improving energy efficiency while maintaining constraint reliability.
2Strength
If hard cushioning material is used to maintain structural integrity, then the battery module structure is stable, but the surface pressure uniformity deteriorates
Solution Approach 1:
The invention uses composite cushioning material comprising a corrugated plate structure with soft resin coating. The corrugated plate provides structural integrity and mechanical strength, while the soft resin coating (with specific hardness E40-E60) provides conformability and uniform pressure distribution, combining both requirements in a single composite component.
Solution Approach 2:
The invention applies different material properties to different parts of the cushioning structure. The bulk corrugated plate structure maintains rigidity for structural support, while the surface layer uses soft resin with controlled hardness to ensure uniform pressure contact. This local differentiation of material properties resolves the contradiction between overall strength and contact uniformity.
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 enhances the uniformity of surface pressure on battery cells, improving energy distribution and reducing hysteresis loss, thereby increasing the efficiency and stability of the battery module.
Implementation Method 1
a cushioning material disposed between the plurality of battery cells and/or between the battery cell stack and each of the plate members. The cushioning material includes a corrugated plate spring having concave portions and convex portions that are alternately and continuously arranged
Implementation Method 2
On an outer surface or an inner surface of each of the battery cells that faces the cushioning material, a soft resin having a hardness of E40 or less or E60 or more is present
Data Source
AI summary
Provided is a battery module including: a battery cell stack in which a plurality of battery cells are stacked; a pair of plate members provided at opposite ends of the battery cell stack in a stacking direction; and a cushioning material disposed between the plurality of battery cells and/or between the battery cell stack and each of the plate members, the cushioning material including a corrugated plate spring including a concave portion and a convex portion that are alternately and continuously arranged, and extending in a predetermined direction, wherein on an outer surface or an inner surface of each of the battery cells that faces the cushioning material, a soft resin having a hardness of E40 or less or E60 or more is present.