Multi-Layer Side-Terminal Battery Module for Compact Pack Layout
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Solution Overview
Problem
Existing battery modules for heavy-duty vehicles are not optimized for space efficiency, reliability, robustness, and cost-effectiveness, particularly in configurations using prismatic side terminal battery cells.
Innovation Solution
A battery module design featuring prismatic side terminal battery cells arranged in multiple layers, with each layer comprising battery cells stacked along the longitudinal direction and secured by straps, and covered by end plates to create a compact, robust, and cost-effective configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in multiple layers stacked along the longitudinal direction, then energy density and space efficiency are improved, but structural complexity and manufacturing difficulty increase
Solution Approach 1:
The battery module is segmented into multiple layers of battery cells stacked along the longitudinal direction. Each layer is independently supported by end plates, allowing for modular assembly and reduced overall structural complexity while maximizing energy density through compact multi-layer arrangement.
Solution Approach 2:
The patent transitions from a single-layer arrangement to a multi-layer three-dimensional configuration. By stacking battery cells vertically in multiple layers along the longitudinal direction, the design achieves higher space efficiency and energy density without significantly increasing manufacturing complexity, as each layer follows a similar structural pattern.
2Reliability
If end plates are provided for each layer to support and protect battery cells, then reliability and robustness are improved, but the number of parts and cost increase
Solution Approach 1:
The end plates serve multiple functions simultaneously: they support the battery cells, protect them from external forces, provide mounting positions for straps, and facilitate thermal management. This multi-functionality reduces the need for additional specialized components, thereby maintaining reliability while controlling the number of parts.
Solution Approach 2:
The patent combines multiple protective and supportive functions into single integrated end plate components. Rather than using separate elements for support, protection, and attachment, these functions are merged into the end plates, which are secured to the battery cells using straps that integrate with the same structural elements.
3Strength
If straps are used to fix battery cells and end plates together, then structural rigidity is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
Straps made of flexible material are used to secure the rigid end plates to the battery cells. These flexible straps can be easily wrapped around and fastened, providing strong structural connection while allowing for simple manual or automated assembly. The flexibility of the straps compensates for minor dimensional variations, simplifying the assembly process.
4Volume of stationary object
If battery cells are tightly packed in a compact configuration, then volume efficiency is improved, but cooling efficiency and thermal management become more difficult
Solution Approach 1:
The compact battery module is segmented into multiple layers with end plates positioned at regular intervals. This segmentation creates channels and pathways for coolant flow between the layers, allowing efficient thermal management despite the tight packing. The end plates serve as mounting points for cooling components and facilitate heat dissipation.
Data Source
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AI summary
A battery module (1) for a battery pack (100), the battery module (1) having a longitudinal extension in a longitudinal direction (L), a width extension in a width direction (W) and a height extension in a height direction (H), wherein - the battery module (1) comprises a plurality of battery cells (2) in the form of prismatic side terminal battery cells, - the plurality of battery cells (2) are arranged in at least two layers (L 1, L2, L3) of battery cells, - the battery cells of each layer are stacked together along the longitudinal direction (L) with side terminals (21) thereof facing in a first direction corresponding to the width direction (W) and in a second direction which is opposite to the first direction. A battery pack and a vehicle are also disclosed.