Composite End Plate for Battery Module Expansion Control
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Solution Overview
Problem
Conventional battery modules have low structural strength due to expansion forces from batteries, leading to deformation and weld failure between end and side plates.
Innovation Solution
A composite end plate design featuring a rigid substrate and connecting cylinder, with a positioning connector and fastener system, allows for secure connection to side plates, enabling the battery module to withstand expansion forces and maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional integrated end plates are used with welding, then manufacturing is simple, but structural strength is low due to battery expansion forces causing deformation and weld failure
Solution Approach 1:
The end plate is divided into a substrate and a connecting cylinder that are separately manufactured and then assembled together. The substrate provides overall structural support while the connecting cylinder specifically addresses the weld connection issue with side plates, allowing each component to be optimized independently for its specific function.
Solution Approach 2:
The end plate uses a composite structure combining the substrate and connecting cylinder made from potentially different materials optimized for their specific roles. This allows the substrate to provide general structural integrity while the connecting cylinder provides enhanced connection strength and resistance to expansion forces at the critical weld interface.
2Strength
If rigid end plates are used to counteract expansion forces, then structural strength improves, but the end plates themselves deform and displace under expansion force
Solution Approach 1:
By separating the end plate into substrate and connecting cylinder, the load paths are differentiated. The substrate maintains overall position stability while the connecting cylinder is specifically designed to resist expansion forces through its connection to the side plate, preventing deformation and displacement at the critical interface.
Solution Approach 2:
The connecting cylinder acts as an intermediary element between the substrate and the side plate. It transfers and distributes expansion forces from the battery through the side plate connection to the substrate, preventing direct deformation of the end plate while maintaining positional stability.
3Strength
If welding is used to fix side plates to end plates, then connection is strong, but weld failure occurs under expansion deformation force
Solution Approach 1:
The connecting cylinder is designed as a separate component with specific geometric features (flats, contours) that create multiple contact points and distribution areas for the weld connection to the side plate. This distributes the stress from expansion forces across a larger weld area, preventing localized weld failure while maintaining strong connection.
Data Source
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AI summary
The present disclosure relates to a composite end plate (1) for a battery module, comprising: a rigid substrate (11) comprising a first surface (11a) and a second surface (11b) opposite to each other in a thickness direction (X) of the rigid substrate (11), wherein the first surface (11a) can be provided to face a battery (2) of the battery module, and the rigid substrate (11) comprises two ends (11c) opposite to each other in a width direction (X) of the rigid substrate (11); and a rigid connecting cylinder (12) extending along a height direction (Z) of the rigid substrate (11) and made of different material from that of the rigid substrate (11), wherein the two ends (11c) of the rigid substrate (11) are connected and fixed to two respective rigid connecting cylinders (12), and a portion of the rigid connecting cylinder (12) exposed at a side where the second surface (11b) is located is connected and fixed to an external structural member. When applied to the battery module, the composite end plate (1) can be firmly connected to the side plate (3), thereby effectively counteracting the expansion deformation force of the batteries (2), preventing the overall size of the battery module from becoming large, and enabling safe and reliable use of the battery module.