Battery Press-Fitting Structure for Cell Swelling and Beam Deformation
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Solution Overview
Problem
Battery cells swell during charging and discharging, causing significant deformation of box beams in module-free battery packs, leading to structural failure risks.
Innovation Solution
A press-fitting member with a metal pressing strip and insulation layer is connected to box beams, reducing deformation by distributing swelling forces and providing insulation, enhancing structural stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the battery cell is accommodated between box beams without additional support structures, then the device complexity is reduced, but the box beams experience large deformation and structural failure risk due to battery swelling
Solution Approach 1:
The press-fitting member acts as an intermediary component between the battery cell and box beams. It transfers and distributes the swelling force from the battery cell to the box beams, preventing direct concentrated loading that would cause large deformation and structural failure.
Solution Approach 2:
The press-fitting member is constructed as a composite structure with a metal pressing strip providing mechanical strength and insulation layers providing electrical isolation. This composite design simultaneously achieves structural support and electrical safety functions.
2Reliability
If a press-fitting member is added to reduce box beam deformation, then the structural reliability is improved, but the device complexity increases
Solution Approach 1:
The press-fitting member utilizes thin film structures (insulation layers wrapped around the metal pressing strip) to provide electrical isolation without adding significant structural complexity or volume. This thin film approach maintains structural reliability while minimizing complexity increase.
3Strength
If the metal pressing strip is directly contacted with the battery cell, then the structural strength is sufficient to resist swelling force, but the risk of electrical conduction and high-voltage arcing increases
Solution Approach 1:
The press-fitting member is constructed as a composite structure with a metal pressing strip providing mechanical strength and insulation layers providing electrical isolation. This composite design simultaneously achieves structural support and electrical safety functions.
Solution Approach 2:
The insulation layers act as intermediary barriers between the metal pressing strip and the battery cell, preventing direct electrical contact while allowing the metal strip to transmit mechanical pressing force to resist battery swelling.
Data Source
AI summary
A battery includes a box, a battery cell, and a press-fitting member. The box includes at least two box beams spaced apart along a first direction. The battery cell is accommodated in the box and disposed between the two box beams. Two ends of the press-fitting member are respectively connected to the two box beams, the press-fitting member is arranged on a side of the battery cell along a second direction, and the second direction intersects the first direction. The press-fitting member includes a first pressing strip and a second pressing strip extending along the first pressing strip. The first pressing strip includes a metal pressing strip and a first insulation layer covering a surface of the metal pressing strip. The second pressing strip is an insulating member fixedly connected to the metal pressing strip.