Rechargeable Battery Module Barrier Design
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Solution Overview
Problem
Conventional rechargeable battery modules face challenges in achieving both sufficient structural strength and efficient heat dissipation, with barriers either increasing manufacturing costs or exhibiting structural weakness, and difficulties in welding due to the use of the die casting method.
Innovation Solution
The implementation of a rechargeable battery module with barriers composed of multiple plates having protrusions and junction portions, where the plates are welded together using ultrasonic or laser welding, providing a strong and efficient cooling structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If barriers are designed with sufficient strength to maintain unit battery shape, then structural strength is improved, but manufacturing cost increases and cooling passage design is restricted
Solution Approach 1:
The barrier is divided into multiple plates (first plate, second plate, third plate, fourth plate) that are joined together. This segmentation allows each plate to contribute to the overall strength while maintaining manufacturability through standardized components that can be produced using injection molding rather than expensive die casting methods.
2Temperature
If barriers are designed for efficient heat dissipation, then cooling efficiency is improved, but structural strength decreases
Solution Approach 1:
Different regions of the barrier structure serve different functions: the plates provide structural strength while the spaces between plates and the channels formed by protrusions provide cooling passages. This local differentiation allows the barrier to simultaneously achieve both structural integrity and efficient heat dissipation.
3Strength
If barriers are manufactured using die casting method to ensure improved strength, then strength is improved, but welding becomes difficult
Solution Approach 1:
The manufacturing method is changed from die casting to injection molding, which produces barriers with surfaces suitable for welding. This parameter change in the manufacturing process enables both sufficient strength and ease of welding, resolving the contradiction between improved strength and welding difficulty.
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
This design enhances the structural strength of the barriers while improving heat dissipation and welding capabilities, ensuring reliable performance and minimizing thermal distortion in high-power applications like hybrid electric vehicles.
Implementation Method 1
The plurality of plates are welded together by either ultrasonic welding or laser welding
Implementation Method 2
The plurality of plates are welded together by either ultrasonic welding or laser welding
Data Source
AI summary
A rechargeable battery module includes a plurality of unit batteries disposed apart at predetermined intervals and barriers interposed therebetween. The barriers include a plurality of protrusions and a plurality of plates with at least one junction portion. The junction portion on one plate is fixed to another plate opposing the one plate.