Battery Module Duct Beam Structure for Impact Resistance
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Solution Overview
Problem
Existing battery modules lack sufficient impact resistance when subjected to external forces, particularly in vehicle applications, which can cause battery cells to jump out or become dislodged.
Innovation Solution
A battery module design featuring a duct system with a beam structure formed by attaching a duct to an attachment-target member, comprising case bodies, which includes wall portions that extend in a direction orthogonal to the battery cells, forming a high-rigidity structure to absorb impacts and prevent cell displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple duct structure is used for gas flow, then the device complexity is reduced, but the impact resistance deteriorates
Solution Approach 1:
The duct is designed with curved surfaces instead of sharp angles, creating a streamlined shape that redirects impact forces along the curved paths. The curved outer surface and internal flow passages distribute mechanical stresses more evenly, preventing stress concentration points that would occur with straight-edged duct designs.
Solution Approach 2:
The duct incorporates three-dimensional wall portions extending in multiple directions (first wall portion, second wall portions, third wall portion, and fourth wall portions) to create a spatial beam structure. This multi-dimensional configuration provides impact resistance in various directions simultaneously, transforming a simple linear gas conduit into a robust structural element.
2Strength
If wall portions with large thickness are used to increase rigidity, then the impact resistance is improved, but the volume of the duct increases
Solution Approach 1:
The duct wall is divided into multiple functional segments: a thin outer skin for gas flow and thicker internal beam portions for structural support. The first wall portion, second wall portions, third wall portion, and fourth wall portions are strategically thickened only where needed to form the beam structure, while other areas maintain minimal thickness for gas flow efficiency.
Solution Approach 2:
The duct employs a composite structural design combining thin-walled sections for fluid flow with thickened rib/reinforcement sections for mechanical strength. This composite approach allows different parts of the duct to have optimized thicknesses - thin where gas flow is prioritized and thick where impact resistance is critical.
Data Source
Figure 1
Figure 2
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AI summary
A battery module includes: a duct (71) extending in a Y axis direction in which a plurality of battery cells (11) are stacked, to form a flow space (110) for gas; and an attachment-target member (30) to which the duct (71) is attached. The attachment-target member (30) has a first wall portion (111) and a pair of second wall portions (116) each rising from the first wall portion (111) in a Z axis direction, the pair of second wall portions (116) being provided with a space being interposed therebetween in an X axis direction. The duct (71) is disposed between the pair of second wall portions (116). The duct (71) has: a third wall portion (136) facing the first wall portion (111) in the Z axis direction with the flow space (110) being interposed therebetween; and a pair of fourth wall portions (131) extending, in the Z axis direction toward the first wall portion (111), from both end portions of the third wall portion (136) in the X axis direction, the pair of fourth wall portions (131) respectively facing the pair of second wall portions (116) in the X axis direction.