Battery Pack Sub-Module Structure for Swelling-Induced Warpage
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Solution Overview
Problem
Conventional battery packs face issues with excessive warpage of frame members and degradation of battery cell life due to swelling phenomena during charging and discharging, as existing compression methods fail to adequately absorb deformation.
Innovation Solution
A battery pack design featuring a first sub-battery module fixed to the bottom of a pack frame with second sub-battery modules that move along connection portions, utilizing frame members made of glass fiber reinforced plastic or carbon fiber reinforced plastic to absorb expansion and reduce pressure deviations, while end plates and frame members provide additional stability and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery cells are fixed rigidly to the module frame, then structural stability is improved, but warpage and degradation occur due to swelling during charging and discharging
Solution Approach 1:
The patent applies the dynamics principle by making the module frame movable rather than rigid. The frame is designed to move along with the battery cells during swelling and contracting cycles, allowing the structure to adapt dynamically to volume changes. This is achieved through a movable frame design that can shift position while maintaining electrical connections, thus preventing warpage and degradation caused by rigid constraints.
Solution Approach 2:
The patent applies parameter changes by modifying the physical state and properties of the module frame. The frame transitions from a static, rigid structure to a dynamic structure with variable position and flexibility. The movable frame can change its spatial configuration to accommodate cell swelling, transforming the structural parameters to maintain both stability and reliability throughout the battery's operational life.
2Manufacturing precision
If compression pads are used to fix battery cells, then initial positioning is improved, but deformation and swelling portions form as swelling increases
Solution Approach 1:
The patent replaces static compression pads with a dynamic movable frame system. Instead of relying on fixed compression elements that create localized stress points and deformation, the entire frame moves dynamically to distribute and accommodate swelling uniformly across all battery cells, preventing the formation of swelling portions and maintaining proper cell shape throughout operation.
3Quantity of substance
If battery cell capacity is increased, then energy density is improved, but swelling amount and displacement increase
Solution Approach 1:
The patent addresses the volume increase from higher capacity cells by implementing a movable frame that can dynamically adjust to larger swelling volumes. The frame's ability to move and reposition allows it to accommodate the increased displacement associated with high-capacity cells, maintaining structural integrity while supporting greater energy storage without being constrained by fixed dimensions.
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 effectively prevents excessive warpage and degradation of battery cells by allowing the second sub-battery modules to move and absorb pressure, maintaining the structural integrity and extending the life of the battery cells.
Implementation Method 1
utilizing frame members made of glass fiber reinforced plastic or carbon fiber reinforced plastic to absorb expansion and reduce pressure deviations
Data Source
AI summary
A battery pack includes a battery module including a first sub-battery module and a pair of second sub-battery modules disposed on both sides of the first sub-battery module, respectively; a pack frame on which the battery module is mounted; and a pair of connection portions that penetrate through the upper and lower portions of the first sub-battery module and the pair of second sub-battery modules, respectively. Both sides of the pair of connection portions are fixed to the side surface portion of the pack frame. The first sub-battery module is fixed to the bottom surface of the pack frame. The second sub-battery module moves along the longitudinal direction of the connection portion.