Battery Module Case Geometry to Reduce Main Plate Sagging
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Solution Overview
Problem
The existing battery modules experience significant deformation, particularly sagging in the downward direction, due to the load from the cell assembly and busbar assembly, which increases assembly difficulty and affects the reliability of the battery pack.
Innovation Solution
A battery module design featuring a case with a main plate and side wall, where the central portion of the main plate is formed to protrude further than the end region, reducing deformation and enhancing assembly stability. The case is manufactured using a two-stage pressing process, including a first pressing process to form the basic shape and a second pressing process to deform the central portion for reduced sagging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a flat main plate is used in the case, then the manufacturing process is simple, but the case deforms (sags) under load from cell assembly and busbar assembly
Solution Approach 1:
The central portion of the main plate is pre-formed to protrude in the first direction before assembly, creating a preliminary shape that compensates for expected sagging under load. This preliminary action prevents deformation during operation without requiring complex manufacturing processes.
Solution Approach 2:
Only the central portion of the main plate is formed to protrude, while the end regions remain flat. This localized quality change provides structural support exactly where needed to prevent sagging, rather than making the entire plate complex.
2Ease of operation
If the central portion of the main plate protrudes further than the end region, then assembly difficulty is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The main plate has different local geometries: the central portion protrudes further in the first direction compared to the end regions. This local differentiation provides clearance or alignment features that facilitate assembly without making the entire structure complex.
3Productivity
If the case structure is simplified, then manufacturing is easier, but deformation under load increases
Solution Approach 1:
The protruding central portion is formed during manufacturing as a preliminary structural feature that proactively prevents sagging under operational load. This maintains reliability while keeping the manufacturing process straightforward.
Solution Approach 2:
The geometry of the main plate is modified by changing the height parameter of the central portion relative to the end regions. This simple parameter change in the case design provides structural support to prevent deformation and ensure reliability.
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 proposed solution effectively reduces the deformation of the battery module, improving assembly efficiency and the overall reliability of the battery pack, while also enhancing its mass production yield and productivity.
Implementation Method 1
a second pressing process of pressing a central portion of the main plate using a pressing mold including a protrusion
Data Source
AI summary
A battery module includes a cell assembly including a plurality of battery cells; and a case including a main plate supporting the cell assembly and a side wall extending from the main plate in a first direction. The main plate includes a central portion and an end region extending from the central portion. At least a portion of the central portion protrudes further in the first direction, than at least a portion of the end region, or is coplanar with the at least a portion of the end region.