Crossbeam Battery Module Assembly for Stronger Cell Stack Clamping

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Solution Overview

Problem

Existing battery modules have complex assembly processes, high weight, and inadequate structural strength, which affects energy density and safety, particularly due to the reliance on bolt connections and sidewalls for positioning and collision protection.

Innovation Solution

A battery module design featuring a case with crossbeams that clamp and fix cell stacks, providing lateral protection and simplifying assembly, while reducing component count and weight through the use of wedge-shaped crossbeams and hollow profiles, and adhesive fixation to a bottom plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If bolt connection is used to fix cell stacks to end plate members, then the cell stacks are securely fixed, but the assembly process becomes tedious and the weight increases

Engineering Contradiction:

Improvefixing strengthVSAvoidassembly process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent removes the end plate members and bolt connections from the battery module structure. Instead of using traditional bolt fixation between end plates and cell stacks, the invention uses structural glue to directly adhere the cell stacks to the bottom plate, eliminating the complex assembly process and reducing weight while maintaining securing function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical bolt connection system with a chemical bonding system using structural glue. This substitution eliminates the need for holes, bolts, and complex assembly procedures while providing adequate fixation strength for the cell stacks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If bolt connection and end plate members are used to fix cell stacks, then the cell stacks are securely positioned, but the weight of the battery module increases

Engineering Contradiction:

Improvefixing strengthVSAvoidbattery module weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If only sidewalls of the battery case are used for side anti-collision functionality, then the structure is simple, but adequate anti-collision performance cannot be provided

Engineering Contradiction:

Improvestructure complexityVSAvoidanti-collision performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent divides the battery case into multiple functional components: bottom plate, sidewalls, and crossbeams. The crossbeams are specifically added as separate structural elements positioned between cell stacks to provide dedicated side collision protection, while the bottom plate with integrated positioning structures provides fixation and additional protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent adds crossbeams that extend in the width direction between the sidewalls, creating a three-dimensional protective framework. This dimensional addition provides side collision protection from multiple directions and prevents structural failure during lateral impacts.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Quantity of substance

If multiple cells are stacked and pre-grouped with bolt connections, then the battery module achieves high voltage and capacity, but the energy density is reduced due to increased weight

Engineering Contradiction:

Improvebattery capacityVSAvoidbattery module weight

Core Design Contradiction:

Quantity of substanceVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4297163A1Battery module

Publication Date: 2023.12.27 VOLKSWAGEN AG

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AI summary

The present utility model provides a battery module, comprising: a case, comprising a first plate and a second plate opposite the first plate; and two cell stacks, each cell stack comprising multiple cells stacked in a stacking direction, and the two cell stacks being installed adjacent to each other in the stacking direction between the first plate and the second plate, wherein the battery module further comprises a crossbeam arranged between two adjacent ends of the two cell stacks, such that each of the two cell stacks is subjected to pressure from the crossbeam in the stacking direction. The battery module of the present utility model can simplify the assembly process of the battery module and increase the structural strength of the battery module.