Battery Cell Stack Positioning With Corner Contact Elements
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Solution Overview
Problem
Existing battery assemblies for motor vehicles with electric drive face challenges in achieving precise and stable positioning of battery cells within the housing due to cell swelling, as current methods rely on elastic compression pads and variable-volume mats, which may not provide sufficient stability and precision in cell alignment.
Innovation Solution
The battery assembly incorporates contact elements with inclined planes positioned in the corners of the battery housing, exerting force on the cell stack in a perpendicular direction to press it against a wall, ensuring precise and stable positioning by using a combination of compression pads and contact elements with different elasticities to maintain cell alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastic compression pads are used to brace battery cells, then cell swelling can be absorbed, but positioning precision and stability deteriorate
Solution Approach 1:
The bracing function is divided into two independent components: compression pads for absorbing cell swelling and contact elements with stops for precise positioning. This segmentation allows each component to specialize in its function without compromising the other.
Solution Approach 2:
Contact elements with stops act as intermediary components between the battery cells and housing walls, providing a mechanical reference that ensures precise positioning while compression pads handle the swelling absorption.
2Adaptability or versatility
If variable-volume compression mats are used to adjust contact pressure, then adaptability improves, but device complexity increases
Solution Approach 1:
The compression pads are designed to automatically adapt to cell swelling without requiring active control mechanisms. The pads self-adjust their compression force based on the cell volume changes, eliminating the need for complex variable-volume mechanisms.
3Stability of the object's composition
If latching elements are used to latch the battery cell stack, then positioning stability improves, but ease of assembly deteriorates
Solution Approach 1:
Instead of using latching elements that require active engagement and disengagement operations, the patent uses stops that passively guide and position the battery cells during insertion. The positioning function is inverted from an active latching mechanism to a passive guiding structure.
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
This solution allows for a stable and precise positioning of the cell stack within the battery housing, ensuring defined tensioning and alignment of battery cells, even with cell swelling, through the use of contact elements and compression pads, enhancing the structural integrity and operational efficiency of the battery assembly.
Implementation Method 1
compression pads... which absorb cell swelling caused by operation and are made of an elastic material for this purpose
Implementation Method 2
the contact element is designed to exert force on the battery cells or the component connected thereto in a force-fitting and/or form-fitting manner via the contact surface
Data Source
AI summary
A battery assembly has a battery housing and battery cells arranged parallel to one another in a housing interior in a first transverse direction (X) running perpendicular to an insertion direction. A compression pad is arranged between each of the battery cells. Furthermore, at least one contact element arranged in a corner of the interior of the battery housing is provided with a contact surface which is in contact with a battery cell or a component connected thereto in a force-fitting and/or form-fitting manner. The contact element is designed to exert a force via the contact surface on the battery cells or the component connected thereto in a force-fitting and/or form-fitting manner in a second transverse direction (Z) running perpendicular to the first transverse direction (X) on the battery cells and pressing the battery cells or the component connected thereto in a force-fitting and/or form-fitting manner against a stop.