Battery Spacer With Protrusions For Electric Core Positioning
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Solution Overview
Problem
Conventional battery spacers fail to position electric cores stably, leading to potential damage from friction during assembly and vibration-induced impacts in new energy vehicles, which can cause safety hazards.
Innovation Solution
A battery spacer with protrusions on the inner surface and grooves and liquid guiding slots on the outer surface, along with reinforcing plates and snap connections, is designed to securely position and insulate the electric core tabs, preventing direct contact with the shell and optimizing electrolyte flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery spacers are used, then the structure is simple, but the electric core tabs cannot be positioned stably and are prone to damage
Solution Approach 1:
The battery spacer is divided into multiple functional regions: protrusions for positioning tabs, grooves for receiving electrolyte, and liquid guiding slots for directing flow. This segmentation allows each region to perform its specific function optimally, improving tab positioning stability while maintaining manufacturing feasibility through modular design
Solution Approach 2:
Different regions of the battery spacer are given different local properties: the inner surface has protrusions for mechanical positioning, the outer surface has grooves for electrolyte management, and specific areas have liquid guiding slots. This local differentiation enables the spacer to simultaneously provide positioning, insulation, and fluid guidance functions without requiring a completely complex overall structure
2Productivity
If electric cores are tightly arranged to increase capacity, then the battery volume efficiency improves, but friction during assembly and vibration impacts cause damage to electric cores
Solution Approach 1:
The battery spacer acts as an intermediary component between the electric cores and the shell. It provides positioning protrusions that prevent direct contact and friction between electric cores during assembly, and creates insulation gaps that reduce vibration impacts. This intermediary structure enables tight arrangement for high capacity while protecting against mechanical damage
Solution Approach 2:
The battery spacer is designed with protrusions and grooves that beforehand cushion and distribute mechanical stresses. The grooves receive electrolyte that provides lubrication and cushioning effect, while the protrusions preemptively position electric cores to avoid direct impact during assembly and operation, preventing friction damage before it occurs
3Reliability
If the battery spacer insulates tabs from the shell, then short circuit risk is reduced, but the spacer requires additional insulating structures
Solution Approach 1:
The battery spacer is designed as a multi-functional component that simultaneously provides mechanical positioning through protrusions, electrical insulation through its material composition, and electrolyte guidance through grooves and slots. This universality achieves short circuit prevention without requiring separate insulating structures, as the spacer itself performs the insulation function
Solution Approach 2:
The insulation function is merged with the positioning and fluid guidance functions in a single integrated battery spacer component. The spacer body combines insulating material with structural features (protrusions, grooves, slots) to achieve multiple functions simultaneously, eliminating the need for additional separate insulating structures
4Productivity
If grooves are added to the spacer body for electrolyte flow, then electrolyte utilization improves, but the spacer weight increases
Solution Approach 1:
The battery spacer incorporates grooves and liquid guiding slots that create a porous-like structure for electrolyte flow. These channels allow electrolyte to penetrate and distribute throughout the battery, improving utilization efficiency. The design uses minimal material removal to create these flow paths, maintaining lightweight construction while achieving effective electrolyte distribution
Data Source
AI summary
A battery spacer, an electric core protection assembly having the battery spacer and a power battery are provided. The battery spacer includes: a spacer body; a plurality of protrusions, each protrusion protruding from an inner surface of the spacer body, extending in a longitudinal direction of the spacer body, and formed by recessing a portion of an outer surface of the spacer body; a plurality of grooves formed in the outer surface of the spacer body, each groove corresponding to one of the plurality of protrusions respectively and formed by recessing the portion of the outer surface of the spacer body; and a plurality of liquid guiding slots formed in the outer surface of the spacer body and extending from the grooves to an edge of the spacer body respectively.