Spring-Loaded Battery Module Structure for Cell Expansion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in minimizing assembly tolerance between battery cells and effectively alleviating cell expansion, which are critical for compact configurations and safety.
Innovation Solution
A battery module design incorporating a mono frame with springs between cell stacks, plates, and a thermistor for temperature monitoring, along with a busbar frame, to minimize assembly tolerance and absorb cell expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery cells are tightly stacked to minimize assembly tolerance, then compact configuration is achieved, but cell expansion during charge-discharge cycles causes structural stress and potential failure
Solution Approach 1:
The patent applies beforehand cushioning by introducing elastic buffering elements (such as elastic sheets or springs) between battery cells before assembly. These elements are pre-installed to compensate for expansion forces that will occur during charge-discharge cycles, preventing structural stress and potential failure while maintaining compact configuration.
Solution Approach 2:
The patent employs parameter changes by using elastic buffering elements that dynamically change their physical parameters (compression, tension, deformation) in response to cell expansion. This allows the buffering structure to adapt to varying expansion forces during different charge-discharge states, maintaining both compactness and structural reliability.
2Manufacturing precision
If rigid fixation is used to minimize assembly tolerance, then compact configuration is achieved, but cell expansion causes increased stress on the fixation structure
Solution Approach 1:
The patent applies dynamics by replacing rigid fixation with dynamic buffering structures that can adapt to cell expansion. The elastic buffering elements (sheets or springs) provide a dynamic response to expansion forces, allowing the fixation structure to maintain manufacturing precision while accommodating stress through elastic deformation rather than rigid resistance.
Solution Approach 2:
The patent employs parameter changes by using elastic buffering elements that change their mechanical parameters (stiffness, deformation) in response to expansion forces. This allows the fixation structure to maintain tight assembly tolerance while dynamically adjusting to stress conditions, preventing stress concentration and structural failure.
3Reliability
If elastic buffering elements are added to accommodate cell expansion, then structural reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies flexible shells and thin films by using elastic buffering sheets that conform to the cell geometry and provide uniform buffering across multiple cells. This approach achieves structural reliability through a simple, scalable design that avoids complex mechanical structures, as the thin elastic films can be easily installed between cells and automatically adapt to expansion forces.
Solution Approach 2:
The patent employs parameter changes by using elastic buffering elements with carefully selected material parameters (elastic modulus, thickness) that provide sufficient buffering capacity without requiring complex structures. By optimizing these parameters, the patent achieves structural reliability through simple elastic deformation rather than complex mechanical mechanisms.
4Device complexity
If simple fixation without buffering is used, then device complexity is minimized, but cell expansion causes assembly tolerance issues
Solution Approach 1:
The patent applies flexible shells and thin films by using elastic buffering sheets that maintain assembly tolerance through elastic deformation. These thin films are simple in structure but effective in maintaining precision, as they can be easily installed between cells and automatically compensate for expansion without requiring complex fixation mechanisms.
Solution Approach 2:
The patent applies beforehand cushioning by pre-installing elastic buffering elements that maintain assembly tolerance before expansion occurs. This simple pre-buffering approach prevents tolerance issues during operation without requiring complex active control mechanisms, as the elastic elements passively compensate for expansion forces.
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 design reduces assembly tolerance and effectively manages cell expansion, enhancing safety through spring-based fixation and temperature detection.
Implementation Method 1
a spring located between the first cell stack and the second cell stack
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery module according to an embodiment of the present disclosure includes a first cell stack and a second cell stack including one or more battery cells, a mono frame receiving the first cell stack and the second cell stack. a spring located between the first cell stack and the second cell stack, a first plate located between the first cell stack and the spring, and a second plate located between the second cell stack and the spring, and the compression direction of the spring is parallel to the stack direction of the one or more battery cells.