Adjustable Battery Module Housing for Variable Cell Assembly Sizes
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Solution Overview
Problem
The manufacturing cost of battery modules and packs is increased due to the need for different sizes of module housings to accommodate varying battery capacities, requiring design modifications and additional production equipment.
Innovation Solution
A battery module design featuring a module housing with at least two frames that can adjust length to fit different cell assembly sizes, using male-female coupling and movable frames to minimize housing size variations, along with a fixing member to stabilize the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the deformation control difficulty increases and uniformity of physical properties deteriorates
Solution Approach 1:
The patent divides the battery pack into multiple battery modules, each with smaller dimensions. This segmentation allows each module to maintain uniform physical properties and controlled deformation characteristics while the overall pack achieves high capacity through aggregation of multiple modules.
Solution Approach 2:
The patent transitions from single large modules to multiple smaller modules arranged in spatial configurations (series/parallel connections). This dimensional reorganization enables the system to achieve high capacity without compromising the deformation control and physical property uniformity of individual modules.
2Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the heat dissipation performance deteriorates
Solution Approach 1:
Dividing the battery system into multiple smaller modules increases the surface-area-to-volume ratio, improving heat dissipation efficiency. Each module can be independently thermally managed, preventing heat accumulation while maintaining high overall capacity.
Solution Approach 2:
By organizing batteries into multiple modules with spatial distribution, the system enhances thermal management capabilities through increased surface area exposure and improved airflow circulation, thereby improving heat dissipation while maintaining high energy storage capacity.
3Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the module consistency deteriorates
Solution Approach 1:
The patent employs segmentation to create multiple smaller modules with consistent physical and chemical properties. This ensures uniform manufacturing quality, electrochemical performance, and aging characteristics across all modules, thereby maintaining high overall capacity without sacrificing consistency.
Solution Approach 2:
Each battery module is designed with localized uniformity in terms of cell selection, arrangement, and physical properties. This local quality control ensures that each module performs consistently, which is essential for maintaining overall pack consistency while achieving high capacity through multiple modules.
4Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the safety risk increases
Solution Approach 1:
The patent divides the battery system into multiple smaller modules, which reduces the propagation of thermal runaway and other safety hazards. Each module can be independently isolated, limiting the impact of failures while maintaining high overall capacity through the aggregation of multiple safe, smaller units.
Solution Approach 2:
By reorganizing the battery architecture into multiple modules with spatial separation, the system enhances safety through physical isolation of potential failure points. This dimensional reorganization allows high capacity to be achieved while reducing safety risks associated with large single modules.
Data Source
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AI summary
The present disclosure relates to a battery module with reduced manufacturing cost and a battery pack comprising the same. To achieve the above-described object, the battery module according to the present disclosure includes a cell assembly including a plurality of secondary batteries, and a module housing in which the cell assembly is received, wherein the module housing includes at least two frames capable of changing a length of the module housing according to a size of the cell assembly.