Battery Module Middle Plate Layout for Spring-Back Fit Accuracy
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Solution Overview
Problem
The middle plate in existing battery modules experiences spring-back deformation due to stamping and bending, leading to low fitting accuracy and large gaps between the middle plate and end plate, which can compromise the welding process and safety of the battery module.
Innovation Solution
A battery module design featuring a middle plate with a partition and connection portion arranged in a straight line, allowing for improved contour accuracy and reduced assembly gaps, combined with a light shielding structure on the partition portion to block laser penetration during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the middle plate is formed by stamping and bending a metal profile, then the middle plate can be manufactured, but spring-back deformation occurs leading to low fitting accuracy and large gaps
Solution Approach 1:
The patent applies preliminary anti-action by designing the middle plate with a bending resistance structure that pre-compensates for spring-back deformation. The connection portion between the partition portion and plate surface is configured with specific geometric features that resist deformation during stamping and bending, counteracting the spring-back effect before it fully develops and maintaining shape stability throughout the manufacturing and assembly process.
Solution Approach 2:
The patent changes geometric parameters of the middle plate structure, specifically the configuration of the connection portion between the partition portion and plate surface. By optimizing the shape, size, and distribution of this connection portion, the design achieves both manufacturability through stamping/bending and resistance to spring-back deformation, thereby improving fitting accuracy while maintaining shape stability.
2Ease of operation
If a large gap appears between the middle plate and end plate, then assembly is easier, but welding quality and safety are adversely affected
Solution Approach 1:
The bending resistance structure serves as a preliminary anti-action measure that pre-prevents the formation of large gaps by counteracting spring-back deformation. This ensures that the middle plate maintains its intended shape and achieves proper fit with the end plate, guaranteeing welding quality while still allowing for ease of assembly through the guided insertion hole design.
Solution Approach 2:
The insertion hole with guide hole section acts as an intermediary structure that facilitates easy assembly while ensuring proper positioning. The guide hole section guides the middle plate into the correct position, allowing assembly ease without compromising welding quality, as the middle plate is pre-positioned accurately before the welding process.
3Reliability
If the middle plate is inserted into the end plate, then the battery module is assembled, but laser may penetrate through the gap and damage internal components
Solution Approach 1:
The bending resistance structure with optimized connection portion prevents gap formation through preliminary anti-action against spring-back deformation. This eliminates the pathway for laser penetration, protecting internal battery components from laser exposure during the welding process while maintaining complete assembly.
Solution Approach 2:
The patent converts the potential harmful effect of laser penetration into a benefit by designing the middle plate structure to inherently prevent gap formation. The bending resistance structure ensures that the middle plate fits tightly against the end plate, transforming what could be a harmful gap into a beneficial tight fit that protects internal components while maintaining assembly completeness.
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
Ensures enhanced assembly accuracy and welding quality while preventing laser exposure to internal components, thereby improving the safety and reliability of the battery module.
Implementation Method 1
At least one side plate surface of the partition portion has a light shielding structure protruding from a plate surface of the connection portion
Data Source
AI summary
A battery module and a battery pack are provided. The battery module includes two end plate assemblies spaced apart in a first direction and a middle plate connected between the two end plate assemblies. The middle plate includes a partition portion and a connection portion distributed in a straight line in the first direction and in a same plane. The middle plate is inserted into and fitted with the corresponding end plate assembly at least through the connection portion. At least one side plate surface of the partition portion has a light shielding structure protruding from a plate surface of the connection portion. The light shielding structure is arranged on at least one side plate surface of the partition portion.