Battery Module Spacer Element for Force Compensation
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Solution Overview
Problem
Existing motor vehicle battery modules for electric or hybrid vehicles face challenges in compensating for forces and tolerances during operation due to cell breathing and production-related component variations, leading to inefficient compression and potential mechanical stress.
Innovation Solution
The use of spacer elements with specific contact faces and projections between battery cells and pressure plates allows for partial surface contact, enabling force and distance compensation, while also providing mechanical spacing and electrical insulation, allowing for homogeneous force distribution and cell expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If full-surface contact between pressure plates and battery cells is used, then pressing force is effectively transmitted, but force and distance compensation for cell breathing and tolerances is lost
Solution Approach 1:
The contact surface between the pressure plate and battery cell is segmented into two distinct zones: a first contact region that transmits pressing force, and a second contact region that provides distance compensation. This segmentation allows the pressure plate to simultaneously achieve effective force transmission and accommodate cell breathing and manufacturing tolerances without requiring full-surface contact.
2Adaptability or versatility
If spacer elements with reduced contact faces are used, then force and distance compensation is enabled, but the area for force transmission is reduced
Solution Approach 1:
The spacer element is designed with non-uniform contact face distribution: a first contact face with larger area optimized for force transmission, and a second contact face with smaller area optimized for distance compensation. This local quality differentiation ensures that each region of the spacer element performs its specific function efficiently, maintaining adequate force transmission area while enabling compensation capabilities.
3Volume of stationary object
If battery cells are compressed to form a tight battery pack, then space utilization is improved, but mechanical stress and tolerance accumulation increase
Solution Approach 1:
The spacer element incorporates a second contact face specifically designed to absorb dimensional variations and mechanical stresses before they propagate through the battery pack. This beforehand cushioning mechanism compensates for cell breathing and manufacturing tolerances, allowing the battery pack to maintain high density while reducing cumulative mechanical stress and improving overall reliability.
Data Source
AI summary
A motor vehicle battery module, in particular for an electric or hybrid vehicle, includes at least two battery cells which are situated laterally next to one another and form a battery pack, two pressure plates which are situated on opposite sides of the battery pack, and at least one spacer element which has a first bearing surface by which the at least one spacer element bears against a side surface of an adjoining battery cell. The pressure plates are arranged in such a way that the at least two battery cells are arranged between the two pressure plates. The bearing surface is smaller than the side surface, which adjoins the spacer element, of the adjoining battery cell, and therefore part of the side surface is unsupported.