Battery Module Assembly for Force-Redirected Terminal Protection
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Solution Overview
Problem
Existing battery modules in electric vehicles lack effective mechanisms to protect components from external stress and electrical conditions, leading to reduced durability and longevity.
Innovation Solution
A battery module design featuring a cover, frame, and current collector assembly that directs forces away from electrical connection regions, includes a series busbar for electrical connection, and uses a potting material to secure components during assembly, enhancing protection and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules use simple structural design without force direction mechanisms, then manufacturing complexity is reduced, but durability and protection from external stress deteriorates
Solution Approach 1:
The battery module structure is segmented into distinct functional components: a cover structure for force management, a frame structure for support, and an encapsulant for electrical connection protection. This segmentation allows each component to specialize in protecting against specific threats, improving overall durability without requiring complete structural redesign.
Solution Approach 2:
The encapsulant acts as an intermediary component between the electrical connections and the external environment. It provides a protective barrier that isolates vulnerable electrical connections from mechanical stress and environmental factors, thereby protecting the electrical system without requiring direct reinforcement of the connection points themselves.
2Reliability
If battery modules include comprehensive protection mechanisms for electrical connections, then reliability improves, but device complexity increases
Solution Approach 1:
The cover structure serves multiple functions simultaneously: it directs external forces away from electrical connections, provides structural support, and creates a protective enclosure. This multi-functionality allows the same component to address both mechanical protection and structural integrity needs, reducing the total number of components required for comprehensive protection.
Solution Approach 2:
The encapsulant is positioned beforehand to surround and protect electrical connections before final assembly is complete. This pre-positioned protective layer ensures that electrical connections are already shielded from potential damage during the assembly process and throughout operation, improving reliability without requiring complex post-assembly protection mechanisms.
3Strength
If battery modules use rigid encapsulant materials for structural support, then strength improves, but susceptibility to external stress increases
Solution Approach 1:
The modulus of elasticity of the encapsulant is specifically controlled to be lower than that of both the cover and frame structures. This parameter change allows the encapsulant to remain relatively compliant and absorb mechanical stress through deformation, rather than rigidly resisting all external forces. This reduces the transmission of harmful stresses to the electrical connections while maintaining sufficient structural support.
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 design improves the durability and longevity of battery modules by effectively managing external stress and electrical conditions, thereby mitigating climate change through reduced greenhouse gas emissions.
Implementation Method 1
The encapsulant can have a modulus of elasticity that is lower than a modulus of elasticity of the cover and a modulus of elasticity of the frame
Implementation Method 2
An assembly for such a battery module can provide guidance to align and secure assembled components and to retain them with a potting material during assembly
Data Source
AI summary
A battery module may include features to support and protect components thereof from external stress and from certain electrical conditions. In particular, a battery module can be provided with components that direct forces away from electrical connection regions, such as at terminals of a battery cell. Such forces can be directed toward other structures that do not define electrical connection regions. A battery module can also be provided with features, such as a series busbar that electrically connects sets of battery cells, that enhance protections from certain electrical conditions. An assembly for such a battery module can provide guidance to align and secure assembled components and to retain them with a potting material during assembly.