Battery Cell Stack Spacer for Thickness Tolerance Compensation
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Solution Overview
Problem
Existing battery cell stacks often experience thickness deviations from predefined set-values, which can lead to inefficiencies and potential safety issues due to uneven pressure and thermal distribution.
Innovation Solution
A battery cell stack spacer comprising a first and second carrier member with tolerance compensation sheets sandwiched between them, allowing for adjustable thickness to compensate for thickness deviations of battery cells and providing thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If battery cells are stacked without a spacer, then the device complexity is reduced, but the thickness deviation from predefined set-value increases
Solution Approach 1:
A battery cell stack spacer is introduced as an intermediary component between battery cells to compensate for thickness deviations. The spacer includes a base layer and at least one compensation layer that can be adjusted in thickness to correct the overall stack thickness, thereby maintaining manufacturing precision without significantly increasing device complexity.
Solution Approach 2:
The thickness parameter of the spacer is made variable through the use of compensation layers with different thicknesses. By selecting or combining compensation layers of specific thicknesses, the overall spacer thickness can be adjusted to compensate for variations in battery cell thickness, thus achieving the predefined set-value for stack thickness.
2Manufacturing precision
If a thick spacer is used to compensate thickness deviation, then the thickness precision is improved, but the volume of the battery stack increases
Solution Approach 1:
The thickness of the spacer is precisely controlled by selecting compensation layers with specific thickness values. This allows for minimal adjustment to achieve the target thickness, thereby compensating for battery cell thickness deviations while minimizing the increase in overall battery stack volume.
3Manufacturing precision
If multiple compensation layers are used to adjust thickness, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Instead of using multiple complex adjustment mechanisms, the patent employs multiple simple compensation layers with different thicknesses. By stacking these layers in combination, precise thickness adjustment is achieved through parameter variation rather than structural complexity.
Solution Approach 2:
The spacer is constructed as a composite structure with a base layer and multiple compensation layers made of different materials or with different thickness properties. This composite approach enables fine-tuned thickness adjustment while maintaining structural simplicity and ease of manufacture.
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 spacer effectively compensates for thickness tolerances, balances swelling or contraction of battery cells, and enhances thermal insulation between battery cell sub-stacks, thereby improving the safety and efficiency of battery cell stacks.
Implementation Method 1
one or more tolerance compensation sheets sandwiched between the first carrier member and the second carrier member
Implementation Method 2
The present invention further relates to a method of assembling a battery cell stack comprising a plurality of battery cells and a battery cell stack spacer according to the invention. Still, the invention relates to a battery comprising a battery cell stack, wherein the battery cell stack comprises a plurality of battery cells and a battery cell stack spacer according to the invention
Data Source
AI summary
In a battery cell stack spacer compensating a thickness deviation of a stack of battery cells, the battery cell stack spacer includes: a first carrier member providing planar support to a base side of a battery cell; a second carrier member providing planar support to a base side of a further battery cell; one or more tolerance compensation sheets sandwiched between the first carrier member and the second carrier member.