Elastic End Plate Structure for Battery Cell Swelling Control
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Solution Overview
Problem
Existing battery modules face challenges in maintaining appropriate pressure between cells due to swelling, which increases the thickness of end plates, making it difficult to compactly configure the module and increasing manufacturing costs.
Innovation Solution
A battery module design that includes a pair of end plates, sub-end plates, and elastic members, such as disk springs, to elastically support the end plates and sub-end plates, allowing for reduced end plate thickness without a separate buffer member, effectively controlling displacement and load changes caused by cell swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the end plate is increased to tolerate swelling pressure, then the reliability of the battery module is improved, but the volume of the battery module increases and manufacturing costs increase
Solution Approach 1:
The end plate is divided into a main body portion and a protruding portion that extends into the battery cell. This segmentation allows the protruding portion to specifically bear the swelling pressure of the battery cell, while the main body portion maintains structural support, enabling thinner overall end plate design while still tolerating swelling forces.
Solution Approach 2:
The invention introduces a protruding portion that extends in the depth direction (z-axis) from the end plate surface into the battery cell. This dimensional extension creates additional pressure-bearing surface area without increasing the planar dimensions of the end plate, allowing swelling pressure tolerance without increasing module volume.
2Strength
If the thickness of the end plate is increased to maintain appropriate pressure between cells, then the strength is improved, but the manufacturing cost increases
Solution Approach 1:
The end plate is segmented into functional zones: the main body for structural support and the protruding portion for pressure application. This segmentation allows each zone to be optimized for its specific function, maintaining pressure maintenance capability while using less material overall, thus reducing manufacturing cost.
Solution Approach 2:
The protruding portion is strategically positioned to contact specific regions of the battery cell where pressure is needed. This local quality approach concentrates material and force where most needed, rather than uniformly thickening the entire end plate, reducing overall material usage and manufacturing cost while maintaining necessary strength.
3Reliability
If a separate buffer member is added between end plates and battery cells to control swelling, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The invention merges the buffer member function directly into the end plate structure by creating a protruding portion that inherently provides swelling control. This integration eliminates the need for separate buffer members, reducing device complexity while maintaining reliable swelling control through the geometric design of the protruding portion.
Solution Approach 2:
The protruding portion of the end plate serves multiple functions: it acts as a structural support element, a pressure-bearing component, and a swelling control mechanism all in one. This multi-functionality eliminates the need for separate dedicated buffer members, reducing component count and device complexity while maintaining reliability.
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
This design maintains appropriate pressure between cells, reduces the likelihood of cell cap breakage, and increases the battery module's capacity by eliminating the need for a separate buffer member, while maintaining the cells in close contact, thus preserving and extending the lifespan of the battery cells.
Implementation Method 1
elastic members respectively between the end plates and the sub-end plates to elastically support the end plates and the sub-end plates
Data Source
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AI summary
Disclosed is a battery module including battery cells aligned in a first direction, a pair of end plates respectively outside outermost battery cells among the battery cells, a pair of sub-end plates between respective ones of the end plates and the outermost battery cells, and elastic members respectively between the end plates and the sub-end plates to elastically support the end plates and the sub-end plates.