Battery Module Spacer Design for Cell Fixing and Cooling
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Solution Overview
Problem
Battery modules for electric and hybrid vehicles face challenges in securely fixing battery cells and maintaining airflow for cooling, as swelling can cause misalignment and disrupt heat dissipation, leading to reduced lifespan and increased internal resistance.
Innovation Solution
A battery module design featuring spacers with upper flange portions and holding grooves, a top plate with hook members, and end plates with protruding portions to securely fasten and space battery cells, ensuring airflow and constant pressure to prevent distortion and imbalance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged closely to increase capacity, then the power and capacity of the battery module increase, but the airflow for cooling is reduced and heat dissipation is impaired
Solution Approach 1:
The battery module is divided into multiple compartments by spacers, creating separate airflow channels between battery cells. This segmentation allows cooling air to flow through defined paths, maintaining effective heat dissipation even when cells are arranged closely together to increase capacity.
2Reliability
If battery cells are fixed securely to prevent swelling and misalignment, then the reliability and lifespan of the battery module increase, but the device complexity increases due to additional fixing structures
Solution Approach 1:
The spacer integrates multiple functions: it provides structural support, creates airflow channels, and incorporates holding grooves that directly engage with protruding portions on battery cell caps. By combining these functions into a single component, the design achieves reliable cell fixation without adding complex separate fixing structures.
Solution Approach 2:
The holding groove structure on the spacer works passively with the protruding portions on battery cell caps to secure cells in position. The design utilizes the natural geometry of the battery cell caps themselves, requiring no additional active fixing mechanisms while maintaining reliable cell stability.
3Temperature
If spacers are used to maintain airflow channels, then the cooling efficiency improves, but the internal volume of the battery module decreases due to additional space occupied by spacers
Solution Approach 1:
The spacers are positioned strategically at specific locations where airflow channels are most needed, rather than uniformly throughout the entire module. This localized approach maintains cooling efficiency in critical areas while minimizing the overall volume consumed by spacer structures.
Data Source
AI summary
A battery module includes a plurality of battery cells arranged in one direction, spacers respectively located among the plurality of battery cells, the spacers including upper end portions and upper flange portions along the upper end portions, a housing accommodating the plurality of battery cells and the spacers, a pair of end plates at respective opposite ends in the arrangement direction of the plurality of battery cells, the pair of end plates being outside of the housing, and a top plate over the plurality of battery cells, the top plate including a lower surface and at least one holding member on the lower surface, the at least one holding member on the lower surface corresponding to at least one holding groove portion in the upper flange portions of the spacers.