Integrated Compression Limiter Battery Plate Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs for electrified vehicles require separate compression limiters that add complexity and mass, and existing designs do not efficiently integrate these components into the pack's structural plates for enhanced mechanical and thermal performance.
Innovation Solution
The integration of compression limiters into the plates of the battery pack, specifically forming a portion of the plate about a longitudinal axis to provide a rigid connection and secure mechanical fasteners, reduces the need for separate components and enhances structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate compression limiters are used in conventional battery packs, then the compression limiting function is provided, but the device complexity and mass increase
Solution Approach 1:
The compression limiter is merged with the endplate to form an integrated component. The endplate includes a compression limiter portion that extends into the battery pack array to engage with cell tabs, eliminating the need for separate compression limiter components while maintaining the compression limiting function.
Solution Approach 2:
The endplate is designed to serve multiple functions: it provides structural support for the battery pack and simultaneously acts as a compression limiter through its integrated compression limiter portion. This multi-functional design reduces the number of separate components needed in the battery pack assembly.
2Reliability
If separate compression limiters are used in conventional battery packs, then the compression limiting function is provided, but the mass of the battery pack increases
Solution Approach 1:
The compression limiter function is combined with the endplate structure, eliminating the need for additional separate compression limiter components. This integration reduces the overall mass of the battery pack while maintaining the necessary compression limiting capability.
3Device complexity
If compression limiters are integrated into plates, then the number of components and mass are reduced, but the manufacturing complexity of the plate increases
Solution Approach 1:
The compression limiter portion is formed as an integral part of the endplate during the plate manufacturing process. By incorporating the compression limiter geometry into the plate design beforehand, the need for separate assembly steps is eliminated, and the integrated component can be manufactured as a single piece using conventional forming techniques.
4Volume of stationary object
If compression limiters are integrated into plates, then packaging space is reduced, but the structural design complexity of the plate increases
Solution Approach 1:
The compression limiter portion is integrated into the endplate structure, eliminating the need for separate components and reducing packaging space. The compression limiter portion includes features such as engagement surfaces and openings for fasteners that are incorporated directly into the plate design.
Solution Approach 2:
The compression limiter portion extends from the endplate into the battery pack array in a direction perpendicular to the main plate surface. This three-dimensional integration allows the compression limiter function to be provided within the existing plate footprint, reducing packaging space without requiring additional lateral space.
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 integration reduces the number of components, mass, and packaging space, while lowering part costs and improving thermal conduction by providing a robust and rigid joint between the plate and the heat exchanger plate.
Implementation Method 1
improving thermal conduction by providing a robust and rigid joint between the plate and the heat exchanger plate
Data Source
AI summary
An exemplary assembly of an electrified vehicle includes a compression limiter integrated into a plate of a battery pack array. An exemplary method includes forming a portion of a plate of a battery pack array about a longitudinal axis to provide a compression limiter.