Belleville End Plate for Battery Cell Stack Pressure Stability
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Solution Overview
Problem
Current battery systems face challenges in maintaining optimal pressure conditions for battery cells due to susceptibility to length or positioning deviations, requiring precise production tolerances and costly adjustments, which can affect performance and safety over the cell's lifetime.
Innovation Solution
A battery system with a deformable end plate featuring a Belleville spring portion that exerts pressure on the cell stack, compensating for production tolerances and swelling, ensuring a consistent pressure despite variations in cell stack length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If rigid end plates with linear or progressive elastic pressure characteristic are used, then structural simplicity is achieved, but susceptibility to length or positioning deviations increases requiring precise production tolerances
Solution Approach 1:
The end plate transitions from a rigid structure to a deformable structure with non-linear elastic characteristics. This parameter change in structural rigidity allows the end plate to adapt to length deviations and positioning variations in battery cells, eliminating the need for extremely precise production tolerances while maintaining structural integrity
Solution Approach 2:
The end plate is designed to be dynamically deformable rather than statically rigid. The non-linear elastic properties enable the end plate to automatically adjust its shape and pressure distribution in response to cell stack variations, providing self-compensation without requiring precise manufacturing tolerances
2Ease of manufacture
If rigid end plates are used, then manufacturing simplicity is achieved, but the ability to maintain optimal pressure over cell lifetime deteriorates due to swelling and length changes
Solution Approach 1:
The end plate material or structure is designed with non-linear elastic properties that change its stiffness characteristics under different loading conditions. This allows the end plate to maintain optimal contact pressure with battery cells even as they swell or change length over time, ensuring consistent pressure without complex adjustment mechanisms
Solution Approach 2:
The deformable end plate acts as a built-in cushioning element that anticipates and compensates for future cell swelling and length changes. The non-linear elastic properties are designed to provide appropriate compliance during cell expansion, maintaining pressure consistency throughout the cell's operational lifetime
3Reliability
If very precise production tolerances are implemented, then pressure consistency is improved, but manufacturing cost increases
Solution Approach 1:
By changing the structural parameters of the end plate to include non-linear elastic properties, the system tolerates broader manufacturing tolerances in battery cell dimensions. This parameter change shifts the solution from requiring precise cell manufacturing to requiring a compliant end plate design, reducing overall manufacturing costs while maintaining pressure consistency
4Manufacturing precision
If intricate adjustment mechanisms are added, then pressure precision is improved, but device complexity and cost increase
Solution Approach 1:
The deformable end plate with non-linear elastic properties serves itself to maintain optimal pressure without requiring external adjustment mechanisms. The inherent material or structural characteristics provide automatic adaptation to cell stack variations, eliminating the need for intricate positioning or adjustment systems during assembly
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 deformable end plate maintains optimal pressure conditions throughout the cell's lifetime, enhancing performance and safety by adapting to length changes and eliminating the need for additional adjustments, thus ensuring reliable operation.
Implementation Method 1
the cell stack frame includes at least one deformable end plate including a base portion and a Belleville spring portion extending from the base portion towards the cell stack, wherein the deformable end plate exerts a pressure onto the cell stack via the Belleville spring portion
Data Source
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AI summary
The present disclosure refers to a battery system (100) comprising a plurality of battery cells (12) arranged to form a cell stack (10), and a cell stack frame (20) accommodating the cell stack (10), wherein the cell stack frame (20) comprises at least one deformable end plate (22) comprising a base portion (221) and a Belleville spring portion (222) extending from the base portion (221) towards the cell stack (10), wherein the deformable end plate (22) exerts a pressure onto the cell stack (10) via the Belleville spring portion (222).