Battery Module Top Plate Fastening for Mechanical Strength
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Solution Overview
Problem
High-power battery modules face challenges in safety and production costs due to inadequate mechanical strength and complex manufacturing processes.
Innovation Solution
A battery module design featuring a top plate with distinct fastening portions made of plastic and stainless steel end plates, including a gas exhaustion path and connecting members to securely align and fix battery cells, enhancing mechanical strength and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional battery module design is used, then the manufacturing process is simple, but the mechanical strength is insufficient leading to safety issues
Solution Approach 1:
The battery module structure is segmented into distinct functional components: end plates for structural support, a top plate for sealing and gas exhaustion, and connecting members for assembly. This segmentation allows each component to be optimized independently for its specific function while maintaining overall structural integrity and safety.
Solution Approach 2:
The patent employs composite material construction by combining different materials for different components - stainless steel for end plates requiring strength and corrosion resistance, plastic for the top plate providing sealing and gas exhaustion pathways. This composite approach enhances overall mechanical strength while maintaining manufacturing feasibility.
2Ease of manufacture
If a conventional battery module design is used, then production costs are high, but the manufacturing process is complex
Solution Approach 1:
By segmenting the battery module into standardized components (end plates, top plate, connecting members), each can be manufactured independently using optimized processes for that specific part, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The top plate integrates multiple functions including sealing, gas exhaustion pathways, and structural support in a single component, eliminating the need for separate parts and reducing assembly steps, thereby lowering production costs while simplifying the manufacturing process.
3Reliability
If the top plate is securely fastened to prevent separation, then safety is improved, but the fastening structure becomes complex
Solution Approach 1:
The fastening function is merged with the structural support function of the end plates. The connecting members serve dual purposes of both fastening the top plate securely and providing structural support, thereby improving safety without adding separate fastening components or increasing overall structural complexity.
Solution Approach 2:
The connecting members are designed as multi-functional elements that simultaneously provide fastening, structural support, and alignment functions. This universality ensures reliable assembly and safety while minimizing the number of components needed, thus avoiding complexity in the fastening structure.
4Manufacturing precision
If distinct fastening portions are used for the top plate, then assembly reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
Different fastening portions are designed with locally optimized features: one end plate receives a protrusion from the top plate, while the other end plate receives a recess. This local differentiation provides precise assembly guidance and reliable connection without requiring complex fastening mechanisms throughout the entire structure.
Solution Approach 2:
Instead of using identical fastening features on both end plates, the patent employs inverted or complementary features (protrusion on one side, recess on the other). This inversion approach simplifies the fastening design by using simple geometric complements rather than complex identical mechanisms, thereby improving assembly reliability without increasing overall complexity.
Data Source
AI summary
A battery module includes a plurality of battery cells aligned in one direction, first and second end plates, the plurality of battery cells being positioned between the first and second end plates, and a top plate covering top surfaces of the battery cells, the top plate including first and second ends connected to the first and second end plates, respectively, via first and second fastening portions, respectively, the first and second fastening portions being different from each other.