Elliptical Insulating Spacer for Battery Cell Gap Control
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Solution Overview
Problem
Existing battery packs face challenges in maintaining a constant gap between cells to prevent contact during cell growth, which can lead to electrical issues and reduced performance.
Innovation Solution
An electrically insulating spacer with an elliptical peripheral shape and hangers that protrude from the body portion, allowing the spacer to be suspended from the terminal and positioned relative to the cell in three orthogonal directions, maintaining a consistent gap between cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cells are arranged closely to maximize battery pack density, then productivity and space utilization are improved, but the risk of cell contact during growth increases leading to electrical issues
Solution Approach 1:
An electrically insulating spacer is introduced as an intermediary component between adjacent cells. The spacer includes a body portion with curvilinear peripheral shape and hangers that protrude from the body portion to engage with cell terminals or housing features. This mediator maintains a constant gap between cells, preventing direct contact while allowing close arrangement for high density.
Solution Approach 2:
The spacing function is segmented into distinct components: the body portion that provides the insulating barrier and the hangers that provide mechanical attachment. This segmentation allows the spacer to be independently positioned and secured between cells without interfering with cell assembly or electrical connections.
2Reliability
If spacers are added to maintain constant gap between cells, then reliability and electrical insulation are improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single spacer component: electrical insulation, mechanical spacing, and attachment to cell structures. The curvilinear body portion provides the insulating barrier while the integrated hangers provide mechanical engagement, eliminating the need for separate insulating sheets and positioning mechanisms.
Solution Approach 2:
The spacer is designed as a universal component that can be applied to various cell configurations and sizes. The curvilinear peripheral shape and hanger design allow the same basic spacer structure to maintain gaps between different cell types and arrangements, reducing the need for multiple specialized components.
Data Source
AI summary
A battery module includes a battery module housing, cells disposed in the battery module housing, and spacers disposed between adjacent cells. Each spacer is electrically insulating and includes a body portion having a curvilinear, for example elliptical, outer peripheral shape. The body portion is suspended from the cell housing by hangers, and overlies a central region of a cell housing surface corresponding to large deflection due to cell growth. In addition, the body portion is spaced apart from a periphery of the cell housing surface.