Prismatic Battery Module Strapping for High-Force Clamping
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Solution Overview
Problem
Existing containment techniques for prismatic electrochemical accumulators, such as straps and turnbuckle devices, are expensive, difficult to implement, and not very flexible, making it hard to exert the necessary clamping force while allowing for easy disassembly and safety around high-voltage terminals.
Innovation Solution
A restraint device with a strapping strap and a tightening mechanism featuring a base with a central slot, movable tensioners, and a clamping rod that allows for controlled tensioning of the strap, enabling high compression force application with reduced bulk and mass, and easy installation and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If transverse tie rods with support plates are used to clamp the battery module, then greater clamping force is achieved, but the device becomes expensive, difficult to implement, and inflexible for disassembly
Solution Approach 1:
The restraint device is divided into modular components: a base element, multiple adjustable restraint elements (straps with turnbuckles), and mounting elements. This segmentation allows each component to perform its specific function independently while maintaining overall system flexibility and ease of assembly/disassembly, resolving the contradiction between achieving high clamping force and maintaining device simplicity.
Solution Approach 2:
The restraint elements are designed to be adjustable rather than fixed. The turnbuckle mechanisms allow dynamic adjustment of strap tension to achieve the required clamping force, while the entire restraint system can be dynamically assembled or disassembled from the battery module, combining high force capability with operational flexibility.
2Ease of manufacture
If a strap and turnbuckle device are used for restraint, then the implementation is simpler, but the clamping force is insufficient for modern electrochemical batteries
Solution Approach 1:
The turnbuckle mechanism provides dynamic adjustment capability, allowing the strap system to generate and maintain high clamping forces comparable to rigid tie rods. The adjustable nature enables precise force control while keeping the overall structure simple and easy to manufacture, resolving the contradiction between ease of manufacture and sufficient clamping force.
3Force
If mechanical clamping methods with support plates are used, then higher clamping force is achieved, but disassembly becomes difficult or impossible
Solution Approach 1:
The restraint system uses separate, modular components (base element, restraint elements, mounting elements) that can be independently assembled and disassembled. This segmentation enables the system to achieve high clamping force during operation while allowing complete disassembly for repair or replacement, resolving the contradiction between force capability and ease of repair.
Solution Approach 2:
The adjustable restraint elements with turnbuckles provide dynamic control over the clamping force, allowing the system to be easily assembled and disassembled by adjusting the restraint elements rather than permanently fixing them to the battery module, thus maintaining ease of repair while achieving high clamping force.
4Reliability
If high-voltage accumulators are contained with rigid structures, then safety is improved, but flexibility and modularity are reduced
Solution Approach 1:
The restraint device is segmented into separate functional elements that can be independently positioned and adjusted around the battery module. This modular approach maintains safety through proper containment while allowing flexible adaptation to different battery configurations and easy reconfiguration for maintenance, resolving the contradiction between safety and adaptability.
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
Enables flexible and modular high-voltage electrochemical accumulator implementation with precise tensioning over a wide range of forces, from a few Newtons to tens of kN, suitable for high-energy-density batteries in electric vehicles, ensuring safety and ease of repair.
Implementation Method 1
the two movable tensioners and the movable pusher being mounted to slide on the base by a sliding connection along a longitudinal clamping direction
Implementation Method 2
a clamping rod adapted to move and constrain the movable pusher in the direction of the first movable tensioner, along the longitudinal clamping direction
Implementation Method 3
the strapping forming a loop around the first movable tensioner by one of its ends, a section of which is disposed between the movable pusher and the first movable tensioner
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
Retaining device for prismatic electrochemical accumulator module (1), this device comprising a strapping strap (4) and a clamping mechanism (5) which includes: - a base (8); - a first movable tensioner (10) and a second movable tensioner (11); - a movable pusher (16); - a clamping rod (18) adapted to move and constrain the movable pusher (16) in the direction of the first movable tensioner (10); the strapping strap (4) forming a loop around the first movable tensioner (10) by one of its ends (24) a section of which is disposed between the movable pusher (16) and the first movable tensioner (10), and forming a loop around the second movable tensioner (11) by the other of its ends (25).