Battery Module Restrainer with Variable Position Coupling
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Solution Overview
Problem
Lithium ion battery modules expand during charging, leading to deformation and increased electrical resistance, making it difficult to attach or detach them, especially in applications like electric cars where multiple modules are mounted, and existing restrainers do not effectively stabilize the expansion.
Innovation Solution
A battery module with a pair of end plates and a restrainer, utilizing a variable position coupling device and a fixed position coupling device, including wedge-shaped or jagged hole and pin configurations, to securely attach the restrainer to the end plates, allowing for adjustable tension to restrain expansion while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a restrainer is used to compress the battery unit to prevent expansion, then the battery module maintains its shape and reduces deformation, but the fixing structure becomes complex and difficult to assemble
Solution Approach 1:
The coupling structure is divided into multiple coupling holes positioned at different locations along the restrainer. This segmentation allows the end plate to be coupled to the restrainer at multiple discrete points, providing stable fixation without requiring a complex continuous coupling mechanism. The segmented approach simplifies assembly while maintaining shape stability.
Solution Approach 2:
The coupling holes serve multiple functions: they allow passage of coupling members (bolts, rivets, or welds), provide positioning features, and enable flexible assembly methods. This multi-functionality reduces the need for additional specialized components, thereby reducing overall fixing structure complexity while ensuring stable restraint.
2Reliability
If the restrainer is tightly fixed to maintain compression force, then expansion restraint is effective, but the assembly and adjustment process becomes difficult
Solution Approach 1:
The coupling holes are positioned to allow the restrainer to accommodate both initial compression during assembly and subsequent expansion forces during operation. The distributed coupling holes enable the restrainer to maintain effective compression force while allowing for assembly adjustments and thermal expansion, thereby achieving reliable expansion restraint without compromising assembly ease.
3Reliability
If multiple coupling points are used to secure the restrainer, then the fixing is more reliable, but the manufacturing process becomes more complex
Solution Approach 1:
The use of multiple discrete coupling holes segmented along the restrainer provides reliable fixation through distributed attachment points. This segmentation approach allows each coupling hole to be manufactured independently using standard drilling and tapping processes, avoiding the need for complex multi-step manufacturing operations. The segmented coupling holes achieve high fixing reliability while maintaining manufacturing simplicity.
4Stability of the object's composition
If the restrainer is made rigid to prevent deformation, then shape stability is improved, but the coupling structure becomes more complex
Solution Approach 1:
The restrainer is designed with localized coupling holes at specific positions rather than a continuously rigid structure. This local quality approach provides shape stability at the coupling points while allowing the rest of the restrainer to maintain appropriate flexibility. The localized coupling features reduce overall coupling structure complexity compared to a fully rigid design, achieving shape stability through strategic positioning of coupling holes.
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 effectively stabilizes the battery module by preventing deformation and maintaining low electrical resistance, even when multiple modules are mounted in a vehicle, ensuring reliable performance and ease of installation.
Implementation Method 1
a wedge bar configured to push and deform a part of the restrainer so as to be matched with the wedge-shaped recess
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A battery module in which a plurality of batteries (1) are connected in a battery unit (10) and a method of fixing a restrainer (40), the battery module including a pair of end plates (50) facing each other; a restrainer (40) coupled to the pair of end plates (50), the restrainer (40) being configured for restraining expansion of the battery unit (10); and a coupling unit for coupling the end plates (50) and the restrainer (40) to each other, wherein the coupling unit includes a variable position coupling device (B) configured to fix the restrainer (40) and the end plate (50) while varying a coupling location between the restrainer (40) and the end plate (50).