Split Panel Array Plate Stiffness for EV Battery Packs

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Solution Overview

Problem

The bulging or swelling of battery cells during charging and discharging operations in electrified vehicle battery packs causes deflection of surrounding array plates, leading to inconsistent array dimensions and packaging challenges.

Innovation Solution

A split panel array plate assembly with an outer and inner panel that nest together, featuring an embossing pattern to increase stiffness without increasing the overall package depth, and mounting legs with aligned openings for secure fastening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single solid array plate is used to package battery cells, then the structure is simple and easy to manufacture, but the plate deflects under battery cell bulging causing inconsistent array dimensions

Engineering Contradiction:

Improvearray plate stiffnessVSAvoidarray plate structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The array plate is divided into multiple discrete array plates that are stacked together. Each individual array plate has reduced stiffness to accommodate battery cell bulging, but the stacked combination provides the necessary overall structural strength. This segmentation allows each plate to flex independently while maintaining dimensional consistency through the stack.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple array plates are combined to form a composite structure. The stack of multiple thinner plates creates a composite system that achieves the required stiffness and strength without requiring any single plate to be overly rigid, thus preventing deflection issues while maintaining manufacturing simplicity.

Inventive Principle:

Principle #40Composite materials

2Strength

If array plate stiffness is increased to reduce deflection, then array plate stiffness improves, but the overall package depth increases

Engineering Contradiction:

Improvearray plate stiffnessVSAvoidpackage depth

Core Design Contradiction:

StrengthVSLength of stationary object

Solution Approach 1:

Instead of using one thick stiff plate that would increase package depth, the structure is segmented into multiple thinner plates stacked together. This segmentation achieves the required stiffness through the stacked configuration rather than through individual plate thickness, thereby avoiding an increase in overall package depth.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stiffness requirement is solved by transitioning from increasing thickness in one dimension to stacking multiple plates in another dimension. Rather than making each plate thicker (increasing package depth), multiple thinner plates are stacked to achieve the necessary structural rigidity without compromising package depth constraints.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If array plates are made more compliant to accommodate battery bulging, then battery cell accommodation improves, but array dimensions become inconsistent

Engineering Contradiction:

Improvebattery cell accommodationVSAvoidarray dimension consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The array plate system is segmented into multiple discrete plates that can each independently accommodate battery cell bulging through slight flexing. The segmented structure allows local adaptation to cell shape changes while the overall stack maintains consistent external dimensions, resolving the conflict between compliance and dimensional consistency.

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If a single thick array plate is used to maintain dimensional consistency, then array dimension consistency improves, but the plate cannot accommodate battery cell bulging

Engineering Contradiction:

Improvearray dimension consistencyVSAvoidbattery cell accommodation

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The rigid single plate is segmented into multiple thinner plates. Each segment can independently flex to accommodate battery cell bulging, while the stacked configuration of all segments together maintains the overall dimensional consistency of the array. This segmentation simultaneously achieves both adaptability and precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the array plate system have different properties - individual plates are made thin and compliant to accommodate local battery cell bulging, while the stacked assembly as a whole provides the rigid dimensional consistency needed for the battery pack structure. This local quality differentiation resolves the contradiction between flexibility and rigidity.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11724604B2Split panel array plate assemblies for electrified vehicle battery packs

Publication Date: 2023.08.15 FORD GLOBAL TECH LLC

AI summary

This disclosure details battery assemblies for use within electrified vehicle battery packs. An exemplary battery assembly includes a grouping of battery cells and an array plate assembly contacting a portion of the battery assembly. The array plate assembly may embody a split panel design that includes an outer panel and an inner panel that are arranged to nest together. One or both of the outer panel and the inner panel may include an embossing pattern. Among various other advantages, the split panel design increases the stiffness of the array plate assembly without significantly increasing the overall package depth of the array plate assembly or the battery assembly.