Battery Module Side Plate Segmentation for Cell Fixation
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Solution Overview
Problem
Existing battery modules face challenges in achieving a balance between being lightweight, compact, and safe, particularly in high-power applications like electric vehicles, where they need to withstand external forces without compromising safety or efficiency.
Innovation Solution
A battery module design featuring a casing with end plates, side plates, and a cover that securely fasten battery cells using offset extension and seating portions, flange portions, and partition walls to prevent movement and enhance safety, while also allowing for efficient assembly and heat management through strategically placed openings for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are loosely arranged in the casing, then the battery module is easier to assemble and lighter, but the battery cells can be moved by external forces compromising safety
Solution Approach 1:
The side plates are segmented into multiple functional portions: a wall portion for supporting battery cells, a seating portion for receiving the cover, and an extension portion for securing the cover. This segmentation allows each portion to perform its specific function efficiently while maintaining overall structural integrity and safety.
Solution Approach 2:
The extension portion protrudes outward from the side plate in a direction perpendicular to the wall portion, creating a three-dimensional structure that provides additional securing capability without increasing the footprint area, thus fixing battery cells firmly against external forces from multiple spatial dimensions.
2Reliability
If the casing structure is reinforced to prevent cell movement, then safety is improved, but the battery module becomes heavier and less compact
Solution Approach 1:
The wall portion, seating portion, and extension portion are merged into a single integrated side plate structure. This merging provides comprehensive protection and fixation functionality without requiring multiple separate components, thereby reducing overall weight while maintaining safety and preventing cell movement.
Solution Approach 2:
The side plate serves multiple functions simultaneously: the wall portion supports battery cells, the seating portion receives and secures the cover, and the extension portion provides additional anchoring. This multi-functionality eliminates the need for separate structural elements, reducing weight while ensuring safety.
3Weight of moving object
If the casing structure is simplified for lightweight construction, then weight is reduced, but the ability to firmly fix battery cells against external forces is compromised
Solution Approach 1:
The side plate is divided into specialized portions (wall, seating, extension) that each contribute to fixation strength. This segmentation allows the structure to achieve high fixation capability through optimized geometry rather than increased material quantity, maintaining lightweight construction.
Solution Approach 2:
The side plate integrates multiple functional geometries (wall portion for support, seating portion for cover reception, extension portion for anchoring) into a unified lightweight structure, achieving composite functionality that provides strong fixation without excessive weight.
4Reliability
If the side plates include offset extension and seating portions, then battery cells are firmly fixed and safety is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple fixation features (wall portion, seating portion, extension portion) are merged into a single side plate component that can be manufactured as one integrated part. This merging reduces the number of separate components requiring assembly, thereby simplifying the overall manufacturing process despite the complex geometry.
Solution Approach 2:
The extension and seating portions are pre-formed as integral parts of the side plate during manufacturing, rather than being added as separate components. This preliminary action eliminates subsequent assembly steps and ensures precise positioning, improving both safety and manufacturing efficiency.
Data Source
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AI summary
A battery module including: a plurality of aligned battery cells each including a terminal, and a casing for housing the battery cells. The casing comprises a pair of end plates each configured to face a wide surface of a battery cell at a respective outer end of the plurality of battery cells; side plates configured to support side surfaces of the battery cells at respective sides of the plurality of battery cells; a cover configured to cover the battery cells, and at least one of the side plates comprises a wall portion, an extension portion offset from the wall portion and a seating portion arranged to receive an end portion of the cover.