Battery Stack Plate Recess Layout for Flat, Warp-Free Molding
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Solution Overview
Problem
Existing battery stack designs face issues with molding defects such as sink marks and warpage due to thick insulating portions, and unevenness caused by recessed portions can lead to damage or lifting of stacked surfaces when a restraining force is applied.
Innovation Solution
The design incorporates a plate with a fitting groove and recessed holes to reduce thickness while maintaining compressive strength, ensuring flat stacked surfaces by using bottomed recessed holes and recesses to prevent sink marks and warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the thickness of the insulating portion is increased to maintain power storage modules at a predetermined interval, then the structural stability and interval maintenance are improved, but molding defects such as sink marks and warpage occur during injection molding
Solution Approach 1:
The insulating portion is divided into multiple segments by forming recessed portions (first recessed portions and second recessed portions) that extend in the plate thickness direction. This segmentation reduces the overall thickness of the insulating portion while maintaining structural stability through the distributed support structure, thereby preventing sink marks and warpage during injection molding.
Solution Approach 2:
The recessed portions are strategically positioned at specific locations where thickness reduction is most beneficial for preventing molding defects. The first recessed portions extend from one plate surface while second recessed portions extend from the opposite surface, creating localized thinning zones that eliminate sink marks without compromising overall structural integrity.
2Manufacturing precision
If recessed portions are provided on the plate surface to reduce thickness and prevent molding defects, then sink marks and warpage are prevented, but unevenness is formed on the plate surface causing damage or lifting of stacked surfaces
Solution Approach 1:
By providing recessed portions from both the first and second plate surfaces (bidirectional segmentation), the plate achieves thickness reduction without creating significant unevenness on either single surface. The recessed portions are distributed symmetrically, maintaining relative flatness of the stacked surfaces while preventing sink marks.
Solution Approach 2:
The first and second recessed portions are positioned asymmetrically relative to each other across the plate thickness, with first recessed portions extending from one surface and second recessed portions extending from the opposite surface. This asymmetric arrangement allows thickness reduction while maintaining surface flatness for stacking.
3Manufacturing precision
If the plate thickness is reduced to prevent molding defects, then sink marks and warpage are prevented, but the compressive strength in the plate thickness direction may be compromised
Solution Approach 1:
The plate is segmented into multiple regions by recessed portions that create a rib-like structure. This segmentation maintains compressive strength by distributing loads across multiple structural elements rather than relying on a single thick section, allowing thickness reduction while preserving mechanical strength.
Solution Approach 2:
The recessed portions extend in the plate thickness direction (third dimension), creating a three-dimensional structural solution. This dimensional approach maintains compressive strength through the created rib structure while reducing the overall thickness that causes molding defects.
Data Source
AI summary
There are provided a plate for a buttery stack and battery stack including: a plate-shaped housing having a fitting groove provided in a recessed shape in a first plate side surface of the plate for the battery stack along a longitudinal direction thereof; a plurality of bottomed first recessed holes formed side by side in a direction orthogonal to a plate thickness direction of the plate for the battery stack, and extending from a second plate side surface opposite to the first plate side surface; and a plurality of second recessed holes formed side by side in the direction orthogonal to the plate thickness direction, and extending from a bottom portion of the fitting groove to be positioned between the two adjacent first recessed holes.