Composite End Plate for Battery Module Expansion Resistance
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Solution Overview
Problem
Conventional battery modules face structural strength issues due to expansion of unit cells, leading to deformation and failure of weld joints between end plates and side plates, resulting in low structural reliability.
Innovation Solution
A composite end plate design featuring a first and second rigid plate made of different materials, with the second rigid plate being used to connect with the side plate via welding, forming a high-strength weld joint that can withstand larger expansion deformation forces, thereby enhancing the structural reliability of the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end plate and side plate are made of aluminum and fixedly assembled by welding, then the manufacturing process is simple and cost-effective, but the weld joint fails when unit cells expand causing deformation and displacement
Solution Approach 1:
The end plate is divided into two separate rigid plates (first rigid plate and second rigid plate) made of different materials. The first rigid plate is connected to the second rigid plate through mechanical connection means (such as positioning grooves, positioning holes, or connecting members), rather than welding. This segmentation allows each plate to be optimized for its specific function while avoiding weld joint failure under expansion forces.
Solution Approach 2:
The end plate uses composite structure with first rigid plate and second rigid plate made of different materials. This composite design combines the advantages of different materials to achieve both ease of manufacture and high reliability, with the mechanical connection between plates providing failure-resistant assembly that withstands unit cell expansion.
2Device complexity
If the end plate is formed as an integral member, then the structural simplicity is maintained, but the structural strength is insufficient to withstand expansion deformation forces
Solution Approach 1:
The end plate is segmented into first rigid plate and second rigid plate that can be assembled together. This segmentation increases structural strength to withstand expansion forces while maintaining relatively simple overall structure. The modular design allows for optimized material selection and connection methods without excessive complexity.
3Strength
If welding is used to fix the end plate and side plate, then the assembly is strong initially, but the weld joint fails when expansion force is applied
Solution Approach 1:
The connection between first rigid plate and second rigid plate is segmented into mechanical connection elements (positioning grooves, positioning holes, connecting members) that provide flexible accommodation of expansion forces without the brittleness of weld joints, maintaining reliability under thermal and mechanical expansion.
Solution Approach 2:
The connection method changes from welding (thermal process) to mechanical connection (physical process). This parameter change in the joining method allows the structure to accommodate expansion forces through mechanical flexibility rather than thermal-affected weld joints, improving reliability under expansion conditions.
Data Source
AI summary
The present disclosure relates to a composite end plate and a battery module. The composite end plate comprises a first rigid plate having a first surface and a second surface opposite to each other in a thickness direction of the first rigid plate, and comprising a first end portion, a first intermediate portion and a second end portion continuously distributed in a length direction of the first rigid plate; and a second rigid plate comprising a first free end, a second intermediate portion and a second free end continuously distributed in the length direction, wherein the first rigid plate and the second rigid plate are made of different materials, the second intermediate portion is disposed opposite to the first surface, the first free end is connected to the first end portion, and the second free end is connected to the second end portion.