Battery Module Wedge Compression for Constant Cell Force
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Solution Overview
Problem
Existing battery module compression systems often increase complexity, weight, and reduce space, and can overcompress battery cells as they swell, leading to performance issues and potential rupture due to static force adjustments.
Innovation Solution
An adjustable wedge apparatus within the battery module that exerts a constant force on battery cells using a bolt and threaded sleeve mechanism, allowing for expansion and deformation to maintain optimal compression and prevent overcompression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If static mechanical compression systems are used to compress battery cells, then the battery cells are secured within the battery module, but the battery cells become over compressed as they swell over time, impacting performance and increasing rupture potential
Solution Approach 1:
The compression system transitions from a static mechanical clamp to a dynamic electrical compression system using expandable electrodes. The electrodes can adjust their compression force in real-time by controlling the expansion state of the battery cells, allowing the system to adapt to cell swelling over time and maintain optimal compression without over-compression.
Solution Approach 2:
The system changes the compression mechanism from mechanical force application to electrical parameter control. By controlling the electrical state of the expandable electrodes (expansion/contraction), the compression force is dynamically adjusted based on cell swelling, preventing both under-compression and over-compression scenarios.
2Reliability
If electrical compression systems are used to adjust compression based on battery cell state and size, then overcompression is prevented, but the systems become complex, cumbersome, heavy, and consume energy
Solution Approach 1:
The expandable electrodes serve multiple functions simultaneously: they act as both the compression mechanism and the battery cells themselves. This eliminates the need for separate compression devices, reducing system complexity, weight, and energy consumption while maintaining the ability to dynamically adjust compression force.
Solution Approach 2:
The compression system is merged with the battery cell structure itself. The electrodes are integrated into the battery module design, combining the energy storage function with the compression function, thereby eliminating redundant components and simplifying the overall system.
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 improves battery performance, extends battery life, and reduces swelling by maintaining a constant compressive force, preventing overcompression and potential damage.
Implementation Method 1
the threaded sleeve includes at least a portion that is configured to deform once the second force is substantially equal to or exceeds a threshold force
Data Source
AI summary
A battery module includes a housing, battery cells disposed within the housing, and a wedge apparatus disposed within the housing and configured to exert a substantially constant force on the battery cells. The wedge apparatus includes a first wedge having a first thick end tapering to a first thin end, and a second wedge having a second thick end tapering to a second thin end, the first wedge and the second wedge positioned such that the first wedge and the second wedge at least partially overlap. The wedge apparatus further includes a tensioning mechanism disposed at least partially in the first opening and the second opening and configured to move the first wedge in a first direction relative to the second wedge causing a width of the wedge apparatus to expand and exert a first force on the plurality of battery cells.