Multifunctional End-Plate Integrating Cooling Connectors
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Solution Overview
Problem
Conventional battery modules face issues with mechanical stability due to uneven distribution of mechanical stress and require additional space for cooling connectors, which decreases capacity and makes the design prone to bending and snapping of cooling connectors.
Innovation Solution
The integration of cooling connectors within the end-plates, combined with a thicker and extruded aluminum profile design that distributes mechanical stress evenly and protects the connectors, allowing for more space for HV/LV connectors without increasing the module's length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling connectors are provided outside the end-plates, then thermal management is enabled, but the module length increases and mechanical stability decreases
Solution Approach 1:
The cooling connectors are integrated into the end-plates, merging the cooling function with the structural end-plate component. This eliminates the need for separate external cooling connector assemblies, thereby reducing module length while maintaining thermal management capability.
Solution Approach 2:
The end-plates are designed to serve multiple functions: structural support, mechanical stability, and integration of cooling connectors. This multi-functionality allows the end-plates to provide both structural integrity and thermal management without requiring additional components that would increase module length.
2Temperature
If cooling connectors are provided outside the end-plates, then thermal management is enabled, but mechanical stability and connector protection deteriorate
Solution Approach 1:
By integrating cooling connectors into the end-plates, the connectors benefit from the end-plates' structural support and protection. The end-plates provide mechanical stability and protect the connectors from external forces, eliminating the vulnerability of externally mounted connectors.
Solution Approach 2:
The end-plates serve as protective structures that beforehand cushion and absorb mechanical stresses, protecting the integrated cooling connectors from bending and snapping forces before they can cause damage.
3Stability of the object's composition
If end-plates are made thicker for structural support, then mechanical stability improves, but manufacturing complexity increases
Solution Approach 1:
The end-plates are designed with optimized thickness parameters that provide sufficient mechanical stability while considering manufacturing constraints. The thickness is carefully selected to balance structural requirements with ease of manufacture.
Solution Approach 2:
The end-plates utilize aluminum alloy materials that provide high strength-to-weight ratio and good manufacturability. The material selection enables achieving mechanical stability with moderate thickness, reducing manufacturing complexity compared to thicker plates made from less optimal materials.
Data Source
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Figure 2A~2B
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AI summary
The present invention provides a battery module with a multifunctional design of end-plates that enables an integration of cooling connectors and/or LV/HV interfaces above or within the end-plates space and to distribute evenly the mechanical-stress on to the top area of the first and last cells of the battery module.