Battery Module Tension Member Resists Deflection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery modules in electric vehicles face deflection issues due to thermal expansion of battery cells, which can lead to detachment of fluid couplings from conduits, compromising the structural integrity and cooling efficiency.
Innovation Solution
Incorporating a tension member, such as a metallic rod, connected to the end plates of the battery module's compression structure adjacent to the conduits, which applies axial tensile forces to resist deflection and maintain the integrity of fluid couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If compression structures are used to retain battery cells, then dimensional stability is improved, but deflection of end plates occurs due to thermal expansion
Solution Approach 1:
The tension member acts as a counterbalancing element that applies a pre-tension force to the end plates, counteracting the deflection caused by thermal expansion of battery cells. This creates a balanced force system where the tensile force from the tension member opposes the compressive and expansive forces from the battery cells, maintaining dimensional stability while preventing deflection.
Solution Approach 2:
The tension member changes the mechanical parameter of the end plates by applying a controlled tensile force that compensates for thermal expansion effects. This parameter change (applying pre-tension) allows the structure to maintain its dimensional stability across varying temperature conditions without requiring the end plates to be significantly stronger.
2Strength
If end plates are made stronger to resist deflection, then structural integrity is improved, but fluid coupling attachment may be compromised due to rigidity
Solution Approach 1:
The tension member provides a controlled counterbalancing force that prevents excessive deflection of the end plates, thereby maintaining the reliability of fluid coupling attachments. By applying a pre-tension force, the end plates remain sufficiently rigid to secure fluid couplings while avoiding the over-strengthening that would cause detachment due to thermal expansion.
3Strength
If tension member is added to resist deflection, then deflection resistance is improved, but device complexity increases
Solution Approach 1:
The tension member extracts the deflection resistance function from the overall compression structure and implements it as a separate, dedicated component. This allows the end plates and compression structures to focus on their primary functions while the tension member specifically addresses deflection resistance, potentially simplifying the design of individual components while maintaining overall structural integrity.
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 tension member effectively prevents deflection of the end plates, ensuring secure attachment of fluid couplings and maintaining the structural stability and cooling efficiency of the battery module, even under conditions of thermal expansion.
Implementation Method 1
Battery modules in electric vehicles face deflection issues due to thermal expansion of battery cells
Implementation Method 2
the first and second walls subject the rod to an axial tensile force
Data Source
AI summary
A battery module according to an exemplary aspect of the present disclosure includes, among other things, an array of battery cells, a compression structure including a first wall and a second wall, at least one conduit configured to convey fluid adjacent the array, and a tension member connected to the first wall and the second wall. The tension member is adjacent the at least one conduit. This disclosure also relates to an electrified vehicle and a method.