Battery Module Pressure Plate Testing for Swelling Fatigue
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Solution Overview
Problem
Existing pressure tests on battery modules are time-consuming and difficult to control, as they simulate battery swelling through repeated charging and discharging, which takes a long time and lacks precision in controlling the swelling pressure.
Innovation Solution
A device and method that includes a pressure plate and driver to simulate battery cell swelling by pressurizing and depressurizing the cells in the same direction as their swelling, using a hydraulic pump and pressure members to apply controlled pressure, with sensors to measure displacement and pressure, and a welding fatigue tester to evaluate the module case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated charging and discharging is used to simulate battery swelling, then the test reflects actual battery behavior, but the test time becomes excessively long
Solution Approach 1:
The patent pre-installs swelling simulation members (such as inflatable bags or elastic elements) within the battery module before the test begins. These members are pre-positioned to directly contact the battery cells and the module case, so that when inflation or expansion is activated, the swelling effect is immediately applied without requiring repeated charge-discharge cycles to accumulate sufficient swelling pressure.
Solution Approach 2:
The patent introduces a swelling simulation member as an intermediary element between the battery cell and the module case. This mediator (such as an inflatable bag filled with fluid or gas, or an elastic foam element) transmits the swelling force from the battery cell to the module case, amplifying and accelerating the swelling effect while allowing direct control over the pressure applied, thereby eliminating the need for time-consuming repeated charging cycles.
2Reliability
If natural battery swelling is used for testing, then the swelling process is realistic, but the pressure control becomes difficult
Solution Approach 1:
The patent incorporates pressure sensors or displacement sensors within the module case or on the swelling simulation members to continuously monitor the swelling pressure or deformation. This feedback information is fed back to a control system that automatically adjusts the inflation pressure or expansion force of the swelling simulation members, maintaining the pressure within a predetermined range and enabling precise control over the swelling conditions throughout the test.
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 solution allows for rapid simulation of battery swelling effects on the module case, enabling precise control of pressure and reducing test time, while accurately assessing the welded portion's fatigue and performance.
Implementation Method 1
a pressure driver configured to apply a pressure to the pressure plate
Implementation Method 2
a pressure plate installed in a middle portion of the module case in a width direction and configured to pressure the battery cells toward the module case
Data Source
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AI summary
A device is provided for performing a pressure test on a battery module. The device may include a module case in which battery cells are accommodated, a pressure plate installed in a middle portion of the module case in a width direction and configured to pressurize the battery cells toward the module case, a pressure driver configured to apply a pressure to the pressure plate, and a controller configured to control a pressure force and a pressure pattern with respect to the battery cells. The pressure plate may be configured to simulate expansion and contraction of the battery cells by repeatedly pressurizing and depressurizing the battery cells.