Composite Battery Module Plate Structure for Lightweight Rigidity
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Solution Overview
Problem
Conventional aluminum plate elements used in battery modules are heavy, expensive, and complex to manufacture, making them unsuitable for achieving reduced weight with high stability.
Innovation Solution
A sandwich structure plate element composed of two separately produced parts with carbon fiber-reinforced thermoplastic organosheets and thermoplastic base bodies, connected via ribs and welding, providing improved bending resistance and weight reduction without using metal materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional aluminum plate elements are used, then high strength and stability are achieved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining thermoplastic base bodies with organosheets containing carbon fibers. This composite structure provides high strength and rigidity comparable to aluminum while significantly reducing weight. The carbon fibers in the organosheet reinforce the thermoplastic matrix, creating a lightweight yet strong plate element suitable for battery module applications.
Solution Approach 2:
The plate element is divided into multiple components: a first base body, a first organosheet, a second base body, and a second organosheet. These segments are produced separately and then connected together. This segmentation allows for optimized manufacturing of each component and enables the use of lightweight composite materials while maintaining overall structural integrity.
2Ease of manufacture
If aluminum plate elements are used, then structural stability is ensured, but manufacturing complexity increases
Solution Approach 1:
The plate element is segmented into a first base body with a first organosheet and a second base body with a second organosheet. Each segment can be manufactured independently using injection molding processes, simplifying production. The segments are then connected through their longitudinal side surfaces, allowing for modular assembly while maintaining structural stability.
Solution Approach 2:
The invention changes the material parameters from conventional aluminum to thermoplastic materials with carbon fiber reinforcement. This parameter change enables the use of injection molding processes for manufacturing the base bodies, significantly simplifying production while the carbon fiber reinforcement maintains the necessary structural stability.
3Strength
If aluminum plate elements are used, then high strength is achieved, but manufacturing cost increases
Solution Approach 1:
The patent uses composite materials consisting of thermoplastic base bodies reinforced with carbon fiber organosheets. This combination provides high strength comparable to aluminum at lower cost. The thermoplastic materials can be manufactured using cost-effective injection molding processes, and the carbon fiber organosheets provide necessary reinforcement without the high material and processing costs associated with aluminum.
Solution Approach 2:
The invention changes the material parameters from aluminum to thermoplastic composites, enabling the use of injection molding technology. This parameter change significantly reduces manufacturing cost while maintaining high strength through the carbon fiber reinforcement in the organosheets.
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 solution achieves significant weight reduction while maintaining high strength and rigidity, enhancing the stability and processability of the plate elements, thus optimizing the battery module's performance.
Implementation Method 1
The organosheets each have a fibrous fabric or fibrous scrim, which is embedded in a thermoplastic plastic matrix. Organosheets are characterized by a particularly low weight but also by high strength and rigidity at the same time. The organosheet preferably comprises carbon fibers, which are embedded in a thermoplastic plastic matrix.
Implementation Method 2
The organosheets each have a fibrous fabric or fibrous scrim, which is embedded in a thermoplastic plastic matrix. The thermoplastic plastic matrix of the organosheet can, for example, be made from polyamide, in particular from polyamide 6.
Implementation Method 3
A sandwich structure plate element composed of two separately produced parts with carbon fiber-reinforced thermoplastic organosheets and thermoplastic base bodies, connected via ribs and welding
Data Source
AI summary
A plate element for a battery module for receiving battery cells of the battery module includes a first plate element part and a second plate element part. The first plate element part is connected to the second plate element part. The first plate element part includes a first base body and a first organosheet arranged on the first base body. The second plate element part includes a second base body and a second organosheet arranged on the second base body.