Elastic Cell Restraining Structure for Modular EV Battery Packs
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Solution Overview
Problem
Existing power battery manufacturing methods for electric vehicles result in low integration efficiency, high manufacturing and maintenance costs, and safety risks due to complex processes and insecure cell fixation.
Innovation Solution
A battery module design featuring a cell restraining structure with an internal frame and external shell that includes elastic elements, thermal insulation, and a cooling system to manage and support cells, enhancing integration, safety, and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cells are fixed directly into a tray of a battery pack by an adhesive (two-level manufacturing), then the number of components is reduced, but the manufacturing process becomes complex and security decreases
Solution Approach 1:
The battery system is divided into modular battery modules, each containing a fixed number of cells (e.g., 5 cells per module). This segmentation allows for standardized manufacturing while maintaining security through modular design. Each module can be independently manufactured, tested, and replaced, reducing overall system complexity while preserving reliability.
Solution Approach 2:
The patent employs a nested structure where battery modules are nested within battery packs. Each module contains cells arranged in specific configurations (e.g., 1串2并 or 2串1并), and multiple modules are combined to form the complete battery pack. This nesting approach simplifies the overall architecture by creating hierarchical layers of organization.
2Productivity
If cells are fixed directly into a tray of a battery pack by an adhesive (two-level manufacturing), then integration efficiency is improved, but maintenance cost increases
Solution Approach 1:
By segmenting the battery system into standardized modules, the patent enables efficient integration during manufacturing while simplifying maintenance. Each module can be independently replaced without affecting other modules, reducing maintenance costs and improving ease of repair compared to a monolithic battery pack design.
Solution Approach 2:
The standardized battery modules are designed to be universally applicable across different battery pack configurations. The same module design can be used in various pack arrangements, allowing for efficient manufacturing through standardization while enabling flexible maintenance strategies where identical modules can be swapped across different positions.
3Power
If power batteries are designed with constantly increasing energy densities, then power demands are met, but manufacturing cost and complexity increase
Solution Approach 1:
The patent addresses high energy density requirements through segmentation by creating standardized battery modules that can be combined in various configurations to meet different power demands. This allows high-energy-density cells to be manufactured using optimized processes at the module level, reducing overall manufacturing complexity while achieving the required power output through modular assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides high integration efficiency, improved thermal management, enhanced safety through elastic control of cell expansion, and optimized thermal runaway protection, while maintaining low maintenance costs.
Implementation Method 1
the elastic element being elastically deformed as being pressed by a predetermined amount by a corresponding cell received in each of the plurality of chambers such that the elastically deformed elastic element exerts a first force to the corresponding cell
Implementation Method 2
the internal frame further comprises a thermal insulating element forming at least one second surface of each of the plurality of chambers, the thermal insulating element supporting the plurality of cells and having a low thermal conductivity
Implementation Method 3
the external shell comprises a cooling element for supporting and cooling the plurality of cells and comprising a cooling plate for forming a third surface of each of the plurality of chambers, the cooling plate being adhered to the plurality of cells via a thermally conductive adhesive
Data Source
AI summary
A battery module includes: a plurality of cells; and a cell restraining structure having an internal frame and an external shell fit with the internal frame to form a plurality of chambers for receiving the plurality of cells respectively so as to package and manage the cells. The internal frame includes an elastic element forming at least one first surface of each chamber, the elastic element being elastically deformed as being pressed by a predetermined amount by a corresponding cell received in each chamber such that the elastically deformed elastic element exerts a first force to the corresponding cell. The elastically deformed elastic element is further pressed or tends to recover in responding to reversible expansion or contraction of the corresponding cell in operation such that a restraining force to the corresponding cell is determined by the first force.