Plastic End Plates for Battery Cell Expansion in Compact Packs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Newly designed hybrid vehicles require a DC power source that can provide higher driving current, improved anti-overheat performance, and reduced fuel consumption without increasing size or volume, which existing battery packs struggle to meet.
Innovation Solution
A battery pack design featuring two end plates made of plastic to absorb expansion deformations, supporting multiple serially connected battery cells, with a control circuit and electronic components mounted on the plates, and a gas discharging system integrated into the pack's structure to maintain compactness and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack uses traditional rigid end plates, then the structural strength is sufficient, but the expansion deformation of battery cells cannot be absorbed, leading to reduced reliability
Solution Approach 1:
The end plate material transitions from rigid to semi-rigid plastic, changing the mechanical parameters to allow controlled deformation. This enables the end plate to absorb battery cell expansion while maintaining sufficient structural strength, resolving the contradiction between reliability and strength.
Solution Approach 2:
The end plate is designed as a flexible plastic component that can deform elastically to accommodate battery cell expansion. This flexible structure maintains reliability by absorbing deformation while preserving necessary structural integrity.
2Power
If the battery pack increases size to meet higher current demands, then the power output is improved, but the volume constraint is violated
Solution Approach 1:
The end plate integrates multiple functions: structural support, electronic component mounting, and circuit board integration. This merging allows the battery pack to achieve higher power output through improved current collection and distribution without increasing overall volume.
Solution Approach 2:
The end plate serves as a multi-functional component: it provides mechanical support, mounts electronic components (relays, fuses, control units), and integrates circuit boards for current management. This universality enables enhanced power capability within the same volume constraints.
3Device complexity
If the battery pack integrates electronic components on end plates, then the device complexity is reduced, but the manufacturing precision requirement increases
Solution Approach 1:
Electronic components and circuit boards are integrated directly onto the end plate, merging previously separate assemblies into a single integrated unit. This reduces overall device complexity while the modular end plate design allows for standardized manufacturing processes that manage precision requirements.
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
The battery pack effectively supports higher current demands, maintains compact size, enhances fuel efficiency by 15%, and reduces CO2 emissions while ensuring the battery cells' longevity through deformation absorption and integrated gas management.
Implementation Method 1
the first end plate and the second end plate are made of plastic materials to absorb expansion deformations of the multiple battery cells while expanding and deforming
Data Source
AI summary
The present disclosure provides a battery pack including a housing, wherein the housing has a bottom portion and side walls extending upward around a periphery of the bottom portion; an upper portion opening is formed at top ends of the side walls extending upward; an upper cover is mounted on the upper portion opening of the housing; and the battery pack comprises: multiple flat battery cells; and a first end plate and a second end plate, wherein when the multiple battery cells are sequentially arranged and mounted into the housing from the upper portion opening, the first end plate and the second end plate are located at two end sides of the sequentially arranged multiple battery cells to laterally fix the sequentially arranged multiple battery cells. The two end plates may absorb deformation of the battery cell while expanding.