Reinforcement Column for Battery Module Load Distribution
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Solution Overview
Problem
Battery modules in xEVs and other energy storage applications face damage from large loads and high impact situations due to lack of sufficient structural reinforcement, which can compromise the integrity of electrochemical cells and circuitry.
Innovation Solution
A battery module design incorporating a reinforcement column within the housing that extends from an internal partition to a front cover, enhancing the load-bearing capacity and distributing loads through ribbing on the cover to improve crush and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules are designed without additional reinforcement structures, then the device complexity is reduced and manufacturing is simpler, but the load bearing capacity and impact resistance are insufficient
Solution Approach 1:
The reinforcement column is integrated with the housing structure, merging the support function into the existing battery module design. The column extends from the first cover through the housing to the second cover, combining structural reinforcement with the housing's protective function, thereby improving load bearing capacity without proportionally increasing overall complexity
Solution Approach 2:
The reinforcement column is pre-positioned within the housing during assembly, providing structural support before the module is subjected to load or impact. The column is inserted through the housing and positioned against internal features, establishing the load path in advance to prevent damage during operation
2Reliability
If reinforcement columns are added to enhance load bearing capacity, then the protection of internal components is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The reinforcement column is designed as a separate, discrete component that can be manufactured independently and then assembled into the housing. This segmentation allows the column to be produced using standard manufacturing processes and simplifies quality control, while still providing reliable protection when integrated into the complete module
Solution Approach 2:
The reinforcement column acts as an intermediary structural element between the housing and internal components. It transfers and distributes loads from the housing to the internal support features, protecting electrochemical cells and circuitry without requiring direct modification of these sensitive components, thereby maintaining ease of manufacture
3Strength
If the housing structure is strengthened with internal columns, then the crush and impact resistance is enhanced, but the weight of the battery module increases
Solution Approach 1:
The reinforcement column provides localized structural strengthening at critical points within the housing where load and impact forces are most likely to affect internal components. Rather than uniformly thickening the entire housing structure, the column concentrates reinforcement where needed, enhancing crush resistance while minimizing additional weight
Data Source
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AI summary
The present disclosure relates to a battery module having a housing with a first cover and a second cover. The battery module includes a plurality of lithium-ion (Li-ion) electrochemical cells disposed in the housing adjacent to the second cover. The battery module also includes a reinforcement column (38) disposed within the housing that extends along a direction from, the second cover to the first cover. The reinforcement column is positioned against the first cover and is coupled to a feature between, the first and second covers, and the reinforcement column is configured to enhance a load bearing capacity of the battery module.