Battery Cell Stack Spacing for Swelling-Stable Module Assembly
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Solution Overview
Problem
Rechargeable battery modules face deformation issues due to the swelling of battery cells, which can affect the module's structural integrity and manufacturing efficiency.
Innovation Solution
The rechargeable battery module design includes a stack of battery cells with increased distances between outermost and adjacent cells, and thicker insulating assemblies at the periphery, to accommodate swelling and minimize deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are arranged with uniform distance in a stack, then manufacturing is simple, but module deformation occurs due to swelling of peripheral battery cells
Solution Approach 1:
The patent applies different spacing distances to different positions of battery cells in the stack. Specifically, a first distance is maintained between adjacent battery cells at the periphery, while a second distance (smaller than the first) is maintained between battery cells at the center. This local differentiation allows peripheral cells with higher swelling tendency to have more expansion space, while central cells are closely packed, thereby preventing overall module deformation while maintaining manufacturing feasibility.
2Shape
If distance between battery cells is increased to accommodate swelling, then module deformation is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent pre-establishes different standard distance values for peripheral and central battery cell positions during the design and assembly planning phase. By determining these distances beforehand and incorporating them into the assembly guide or fixture design, the actual assembly process becomes more straightforward, reducing the real-time precision control burden while ensuring proper spacing for swelling accommodation.
3Ease of manufacture
If uniform insulating assembly thickness is used, then manufacturing is easier, but swelling accommodation is insufficient at peripheral positions
Solution Approach 1:
The patent specifies that insulating assemblies at peripheral positions between battery cells should have a first thickness, while insulating assemblies at central positions should have a second thickness (smaller than the first). This local thickness differentiation ensures that peripheral regions with greater swelling potential have more insulation and expansion space, while central regions maintain compact structure, thereby improving reliability without overly complicating manufacturing.
Data Source
AI summary
An embodiment provides a rechargeable battery module comprising a stack including a plurality of battery cells arranged along a first direction, a plurality of insulating assemblies positioned between the battery cells, a side plate positioned at a first end portion of the stack along a first direction and a second end portion opposite to the first end portion to support the battery cells, and an end plate positioned at a third end portion of the stack and a fourth end portion opposite to the third end portion along a second direction crossing the first direction to support the battery cells. The stack is positioned in a space surrounded by the side plate and the end plate, and a distance between at least the outermost battery cell disposed on the periphery of the stack and the battery cell adjacent to the outermost battery cell among the battery cells is at least greater than a distance between battery cells positioned adjacent to the center of the stack.