Composite End Plate Resists Battery Expansion Forces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional battery modules experience structural weakness due to expansion and deformation of batteries, leading to potential failure of welding seams between end plates and side plates, which compromises the reliability and safety of the battery module.
Innovation Solution
A composite end plate design featuring a rigid base plate and a connecting plate made of different materials, with a stepped shape and detachable connection, provides a robust and lightweight structure that resists expansion forces by allowing flexible material selection and a high-strength welding seam, enhancing the structural reliability of the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-component aluminum end plates are used, then manufacturing is simple and cost is low, but structural strength is insufficient to resist battery expansion forces
Solution Approach 1:
The end plate is divided into multiple components: a first end plate, a second end plate, and a connecting plate. These segmented components are connected through welding to form a composite structure that provides enhanced structural strength to resist battery expansion forces, while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The end plate system uses composite construction with multiple aluminum plates and connecting plates of different thicknesses and configurations. This composite structure combines the advantages of different component geometries and material distributions to achieve superior mechanical strength compared to single-component designs.
2Reliability
If end plates and side plates are fixedly mounted through welding, then connection strength is high, but welding seams fail under battery expansion forces
Solution Approach 1:
The connection structure is segmented into multiple welding joints distributed across the end plates and connecting plates. This segmentation distributes the expansion forces across multiple connection points rather than concentrating stress at single welding seams, improving overall connection reliability.
Solution Approach 2:
Different regions of the end plate structure have different plate thicknesses and configurations optimized for their specific functional requirements. The connecting plates and end plates are designed with varying local properties to distribute stress and enhance welding seam reliability in critical areas.
3Strength
If aluminum end plates are used, then weight is low, but structural integrity deteriorates under expansion forces
Solution Approach 1:
The end plate system uses segmented aluminum plates of different thicknesses strategically positioned to provide structural integrity where needed while minimizing material usage. This segmentation allows the structure to maintain strength under expansion forces without requiring uniform thick plates throughout, thus controlling weight.
Solution Approach 2:
The composite aluminum plate structure combines plates of different thicknesses and configurations to achieve optimal structural integrity-to-weight ratio. The varying plate geometries and arrangements create a lightweight yet strong framework that resists battery expansion forces effectively.
Data Source
AI summary
The disclosure relates to a composite end plate and a battery module. The composite end plate comprises a first surface and a second surface, and comprises a rigid base plate comprising two ends and a rigid connecting plate extending in a height direction of the composite end plate. The rigid connecting plate and the rigid base plate are made of different materials. The rigid connecting plate comprises a first connecting segment, an intermediate transitional segment and a second connecting segment. The second connecting segment comprises a transferring section connected to the intermediate transitional segment and a free-end section. The two ends are fixedly connected to two respective rigid connecting plates. The first connecting segment and the free-end section are embedded in the rigid base plate. The transferring section can be fixedly connected to an external structural component. The composite end plate can be firmly connected to the side plate.