Battery Pack End Plate Structure for Cell Stack Length Deviations
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Solution Overview
Problem
Existing battery pack assembly methods face challenges in ensuring smooth assembly and extending the lifespan of battery cells, particularly due to issues with length deviations and pressure differences between cell stacks.
Innovation Solution
A battery pack design featuring an end plate with a spacer and sealing members that can deform elastically, allowing for precise alignment and sealing of cell stacks within a housing, while a manufacturing method aligns and assembles the end plates and spacer to absorb length errors and maintain consistent pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid end plates are used to ensure precise alignment, then manufacturing precision is improved, but adaptability to length deviations deteriorates
Solution Approach 1:
The end plate incorporates an elastic member (such as an elastic plate or rubber element) that can deform elastically in the direction parallel to the first direction. This flexible component allows the end plate to adapt to length deviations of the cell stack while maintaining precise alignment and contact, resolving the contradiction between rigidity for precision and flexibility for adaptability.
Solution Approach 2:
The end plate design allows for changes in the physical state or properties of the elastic member, enabling it to deform and adjust its shape according to the actual length of the cell stack. This parameter change approach allows the same end plate structure to accommodate various length deviations while maintaining alignment precision.
2Use of energy by moving object
If fixed pressure is applied to cell stacks, then energy density is improved, but reliability deteriorates due to pressure deviations
Solution Approach 1:
The end plate transitions from a static, fixed-pressure structure to a dynamic system where the elastic member can adjust its deformation based on the cell stack's actual length. This dynamic adaptation ensures that consistent pressure is applied to the cell stack, preventing pressure deviations that would compromise reliability while maintaining high energy density.
Solution Approach 2:
The elastic member in the end plate acts as a feedback mechanism that automatically adjusts to the cell stack's length. When the cell stack length varies, the elastic member deforms accordingly to maintain optimal contact pressure, ensuring both high energy density and pressure consistency without requiring external control systems.
3Adaptability or versatility
If complex sealing structures are added to accommodate length deviations, then adaptability is improved, but device complexity increases
Solution Approach 1:
The elastic member in the end plate serves multiple functions simultaneously: it provides sealing, accommodates length deviations, maintains pressure, and ensures alignment. This multi-functional design achieves adaptability to length errors without adding complex separate sealing structures, thereby avoiding increased device complexity.
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
This design facilitates easy and secure assembly of battery packs, preventing pressure deviations and improving the lifespan by accommodating length errors and ensuring consistent contact between cell stacks and the housing.
Implementation Method 1
The spacer may be elastically deformable. The spacer may be hardened after being injected into the chamber in a liquid state.
Implementation Method 2
The first sealing body may expand and contract in a direction parallel to the first direction in conjunction with a relative movement of the first plate and the second plate. The first sealing body may be elastically deformable.
Data Source
AI summary
A battery pack and a manufacturing method thereof are disclosed. A battery pack includes a housing, a cell stack inside the housing and including a plurality of battery cells arranged along a first direction, and an end plate between the housing and the cell stack, and the end plate includes a first plate configured to contact the housing, a second plate arranged to face the first plate and configured to contact or separate from the cell stack while being moved in a direction parallel to the first direction, a chamber between the first plate and the second plate, and a spacer located inside the chamber such that the second plate contacts the cell stack.