Battery Module Lower Case Grooves for Pouch Cell Delta Fins
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Solution Overview
Problem
Conventional pouch-type secondary battery cells with delta fin portions pose challenges in manufacturing battery modules, as they occupy more space and can cause wrinkling or cracking when accommodated, reducing energy density and requiring new manufacturing methods to consider these protrusions.
Innovation Solution
A method involving extrusion molding and forging operations to create a case for battery modules, with a cooling plate and sidewall member integration, forming accommodation grooves that prevent wrinkling and cracking by maintaining specific curvature radii and depths, allowing for efficient accommodation of delta fin portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pouch-type secondary battery cells with delta fin portions are accommodated in battery modules, then the battery module can accommodate more battery cells, but the delta fin portions cause wrinkling or cracking in the case structure
Solution Approach 1:
The invention performs preliminary action by forming accommodation grooves in the case structure before inserting the battery cells. These grooves are specifically designed to receive and accommodate the delta fin portions protruding from the battery cells, preventing the wrinkling and cracking that would otherwise occur during assembly. The grooves are formed with specific geometric parameters (radius of curvature ≤ 0.2mm, depth ≤ 60% of cooling plate thickness) to ensure proper stress distribution and structural integrity.
2Reliability
If accommodation grooves are formed with small radius of curvature to prevent wrinkling, then structural integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention applies parameter changes by establishing specific numerical constraints for the accommodation groove geometry: radius of curvature of 0.2mm or less, and depth of 60% or less of the cooling plate member thickness. These parameter specifications optimize the balance between preventing wrinkling (requiring small radius) and maintaining structural integrity (requiring controlled depth). The extrusion molding process parameters are also optimized to achieve these geometric requirements while managing manufacturing precision.
3Quantity of substance
If cooling plate member thickness is increased to accommodate deeper grooves, then more battery cells can be accommodated, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention applies partial action by forming accommodation grooves with depth limited to 60% or less of the cooling plate member thickness. This partial depth is sufficient to accommodate the delta fin portions without requiring excessive material thickness. The groove depth is optimized to provide just enough accommodation space while maintaining structural integrity and avoiding the need for overly thick cooling plates, thus balancing battery cell accommodation capacity with device complexity.
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 method enhances energy density by securely accommodating more secondary battery cells while preventing structural issues like wrinkling and cracking, ensuring a robust and efficient battery module design.
Implementation Method 1
an extrusion molding operation in which a metal material is extruded to mold a cooling plate member and a sidewall member of the battery module
Implementation Method 2
a forging operation in which an internal surface of the cooling plate member is pressed with a punch, having an edge of a lower end provided vertically, to form an accommodation groove
Data Source
AI summary
A method for manufacturing a lower case of a battery module includes an extrusion molding operation in which a metal material is extruded to mold a cooling plate member and a sidewall member of a battery module; a forging operation in which an internal surface of the cooling plate member is pressed with a punch, having an edge of a lower end provided vertically to form an accommodation groove; and a forming operation in which an embossed piece, protruding to an external surface of the cooling plate member by forming the accommodation groove, is removed.