Reinforced End Plate for Battery Module Deformation Control

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Solution Overview

Problem

Lithium ion battery modules expand during charging, leading to deformation and increased electrical resistance, making them difficult to attach or detach and reducing their lifespan when used in large power supply units like electric cars.

Innovation Solution

Incorporating reinforcing end plates with parallel supporting bars and beads to enhance structural strength, preventing deformation caused by battery expansion, and including a controller for monitoring battery states.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If lithium ion batteries are used in battery modules for large capacity power supply, then energy storage capacity is improved, but the battery module expands during charging causing deformation and increased electrical resistance

Engineering Contradiction:

Improveenergy storage capacityVSAvoidstructural stability

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The end plate is segmented into multiple reinforcing portions (first, second, third, and fourth reinforcing portions) that are distributed across different locations. This segmentation allows each reinforcing portion to independently support specific battery groups, effectively managing the expansion forces throughout the battery module during charging cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Reinforcing portions are strategically placed at specific locations where batteries are most likely to expand and cause deformation. The end plate has non-uniform thickness and reinforcement distribution, with stronger reinforcement in areas experiencing higher expansion stress, thereby locally addressing the deformation problem without adding unnecessary weight throughout the entire structure.

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If battery modules are deformed due to expansion, then attachment and detachment become difficult, but using larger battery packs exacerbates the deformation problem

Engineering Contradiction:

Improvebattery pack sizeVSAvoidattachment and detachment ease

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The end plate is pre-reinforced with multiple reinforcing portions before the batteries are installed and before expansion occurs. This preliminary reinforcement structure is designed to anticipate and counteract the expansion forces that will occur during charging, ensuring that the end plate maintains its shape and the battery module remains easy to attach and detach throughout its operational life.

Inventive Principle:

Principle #10Preliminary action

3Strength

If end plates are made stronger to prevent deformation, then structural strength is improved, but device complexity increases

Engineering Contradiction:

Improveend plate strengthVSAvoidend plate structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple reinforcing portions are integrated into a single end plate structure that serves both as a structural support element and as a deformation-prevention mechanism. The reinforcing portions are merged with the main body of the end plate, creating a unified component that provides strength without requiring separate additional support structures, thereby avoiding excessive complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8563153B2Battery module having improved end plate

Publication Date: 2013.10.22 SAMSUNG SDI CO LTD

AI summary

A battery module including a row of batteries; and end plates coupled to ends of the row of batteries, wherein the end plates include a reinforcing portion for increasing strength of the end plates.