Dual-Material Cell Module Support for Insulated Load Capacity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current mounted battery systems in electric vehicles face challenges with polymer-based cell modules that have low load capacity and poor fit with battery mounts due to contraction during cooling, leading to increased short circuit potential and instability under operational forces.
Innovation Solution
A dual-material securing system is introduced, comprising an electrically non-conductive side part and a stiffer fixation part made of a material like metal, which is secured to the cell module and battery mount respectively, to enhance electrical insulation and mechanical stability, allowing for better resistance to bending forces and improved clamping loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer material is used for cell module sides to reduce short circuit potential, then electrical insulation is improved, but load capacity and mechanical strength deteriorate
Solution Approach 1:
The side part is constructed as a composite structure with a polymer base material providing electrical insulation, reinforced with stiffening elements made of metal or rigid plastic. This composite design allows the component to maintain electrical non-conductivity while achieving the necessary mechanical strength and load capacity to withstand operational forces during vehicle operation.
2Reliability
If polymer material is used for cell module sides, then electrical insulation is improved, but fit precision with battery mount deteriorates due to cooling contraction
Solution Approach 1:
The side part incorporates stiffening elements that modify the thermal and mechanical parameters of the polymer material. These reinforcement structures reduce excessive contraction during cooling by providing structural support, thereby improving the fit precision with the battery mount while preserving the electrical insulation properties of the polymer base material.
3Strength
If stiff material is used for fixation part to improve load capacity, then mechanical strength is improved, but electrical insulation deteriorates
Solution Approach 1:
The side part employs local quality differentiation by using polymer material in regions requiring electrical insulation (contacting the cells) and incorporating stiffening elements made of conductive material only where mechanical strength is needed (in non-contact areas). This localized material selection allows the fixation part to achieve high load capacity while maintaining electrical insulation where required.
Data Source
AI summary
There is provided a battery assembly comprising a cell module, a side part, and a fixation part. The cell module comprises a plurality of cells. T side part is made of a first material and is secured to a first side of the cell module, wherein the first material is electrically non-conductive. The fixation part is made of a second material and is secured to and extending from the side part, wherein the second material is stiffer than the first material.