Battery Module Frame Alignment for Weld-Accurate Pack Assembly
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Solution Overview
Problem
Existing battery modules face assembly defects due to lack of alignment guides during the assembly process, leading to welding misalignment and defects, particularly in large-sized modules with multiple battery cells.
Innovation Solution
A battery module design featuring a module frame with a lower frame and upper plate, incorporating assembly guide parts and protrusions on the side surface parts, and corresponding grooves on the upper plate to ensure precise alignment and prevent welding defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If welding or coupling is performed to join the upper plate and U-shaped frame without assembly guides, then the manufacturing process is simple, but assembly alignment defects occur due to thickness tolerance variations
Solution Approach 1:
The patent introduces an assembly guide part as an intermediary component between the upper plate and U-shaped frame. This guide part includes a guide protrusion on the upper plate and a corresponding guide groove on the side surface part, which mediate the alignment process during assembly, ensuring precise positioning without complicating the overall manufacturing process
Solution Approach 2:
The assembly guide part is pre-formed on the upper plate and side surface part before the final welding or coupling process. This preliminary action of creating guide protrusions and grooves ensures that alignment is established beforehand, preventing assembly defects during the joining operation
2Adaptability or versatility
If the side surface part is widened to accommodate thickness tolerance, then assembly flexibility increases, but welding misalignment defects occur
Solution Approach 1:
The patent applies local quality by creating a specific guide structure (protrusion and groove) at the critical coupling location between the upper plate and side surface part. This localized feature ensures precise alignment at the welding interface while the rest of the side surface part can maintain its widened structure to accommodate thickness tolerance variations
Data Source
AI summary
The present disclosure relates to a battery module and a battery pack including the same. A battery module according to an embodiment of the present disclosure may includes a battery cell stack in which a plurality of battery cells are stacked, a module frame arranged so as to wrap the battery cell stack, a busbar frame arranged so as to cover the front and rear surfaces of the battery cell stack that is exposed from the module frame, and an end plate arranged so as to cover the busbar frame. The module frame may includes a lower frame for covering the lower part and both side surfaces of the battery cell stack, and an upper plate for covering the upper part of the battery cell stack. At least one assembly guide part may be formed at an edge of the lower frame coupled to the upper plate.