FRP Binding Member for Battery Module Stress Distribution
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Solution Overview
Problem
The deterioration of binding members due to pressure fluctuations in batteries and gas tanks is a significant issue, as the repeated expansion and contraction cause fatigue and stress concentration, leading to premature deterioration.
Innovation Solution
A module design featuring a binding member formed from fiber-reinforced plastic (FRP) with a base fiber layer and a reinforcing fiber layer, where the reinforcing fiber layer has a non-overlapping portion positioned in a region facing the first member, providing enhanced durability against pressure fluctuations by distributing stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a binding member is used to bind a battery or gas tank, then the binding member applies binding load to maintain structural integrity, but deterioration of the binding member occurs due to pressure fluctuation
Solution Approach 1:
The reinforcing fiber layer is positioned specifically on the inner peripheral surface facing the battery or gas tank, creating local reinforcement where pressure fluctuation causes maximum stress. This localized quality enhancement addresses the deterioration issue without requiring uniform reinforcement throughout the entire binding member structure.
Solution Approach 2:
The binding member is constructed as a composite structure with at least two different types of fiber layers: a base fiber layer providing general structural support and a reinforcing fiber layer providing enhanced strength against pressure fluctuation. This composite material approach combines different fiber properties to simultaneously achieve binding load capacity and durability.
2Ease of manufacture
If the binding member is made with uniform fiber distribution, then manufacturing is simplified, but stress concentration occurs during pressure fluctuation leading to deterioration
Solution Approach 1:
Instead of uniform fiber distribution, the fiber layers are arranged with specific local characteristics: the reinforcing fiber layer has higher fiber density and different fiber orientation on the inner peripheral surface compared to other regions. This local quality variation prevents stress concentration while remaining compatible with existing manufacturing processes.
Solution Approach 2:
The fiber layers are arranged with different orientations: the base fiber layer has fibers extending in the circumferential direction while the reinforcing fiber layer has fibers extending in the axial direction. This dimensional arrangement of fibers creates a three-dimensional stress distribution pattern that prevents stress concentration during pressure fluctuation.
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 module effectively restrains deterioration of the binding member caused by pressure fluctuations, as demonstrated by fatigue testing showing increased durability and reduced likelihood of fracture compared to conventional designs.
Implementation Method 1
the reinforcing fiber layer has a non-overlapping portion positioned in a region facing the first member... effectively restrains deterioration of the binding member caused by pressure fluctuations... distributing stress effectively
Data Source
AI summary
A module includes a first member that is a battery or a gas tank in which pressure fluctuation happens along one axis direction, a pair of second members, the second members being arranged on end portions of the first member in the one axis direction, respectively, and a binding member binding the first member and the second members while pressurizing them. The binding member is formed as fiber-reinforced plastic (FRP) containing fiber and resin is revolved. The FRP includes a base fiber layer with a fiber direction along a revolution direction, and a reinforcing fiber layer with a fiber direction different from that of the base fiber layer. The reinforcing fiber layer has a non-overlapping portion between both end portions in a revolved state. The non-overlapping portion is positioned in a region facing the first member.