Battery Module Frame Structure for Swelling-Safe Brazed Cooling Plates
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Solution Overview
Problem
The existing battery modules face issues where the component welding parts, such as the cooling plate, are prone to rupture during the insertion and assembly of the cell block assembly, and may also rupture due to swelling over time, leading to defective modules.
Innovation Solution
The battery module design includes a cell block assembly, a bottom plate with a cooling plate coupled through brazing welding, a frame surrounding the cell block assembly, and end plates. The frame's design, with a stepped sidewall and integrated ceiling part, and the bottom plate's shape help prevent welding part damage during assembly and swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the frame sidewall is spread to both sides during cell block assembly insertion, then the cell block assembly can be inserted into the frame, but the brazing-welding part of the cooling plate mounted under the bottom part of the frame is ruptured
Solution Approach 1:
The frame is designed with a predetermined deformation section in the sidewall that allows controlled spreading. This preliminary design of the deformation path enables the sidewall to spread during assembly without causing uncontrolled stress concentration at the cooling plate welding location, thus preventing rupture while facilitating insertion.
Solution Approach 2:
The deformation section acts as an intermediary element that absorbs and redirects the spreading force. Instead of the spreading force directly transmitting to the cooling plate welding part, the deformation section serves as a buffer zone that manages the mechanical stress, preventing it from reaching the vulnerable welding area.
2Duration of action of moving object
If the battery module is used for a long time and swelling occurs, then the battery module continues to operate, but the welding part of components such as the cooling plate ruptures
Solution Approach 1:
The frame design incorporates a deformation section that provides built-in compliance and stress absorption capacity. This beforehand cushioning effect allows the frame to accommodate swelling of the battery cells over time without transmitting excessive stress to the cooling plate welding parts, thereby preventing rupture during extended service life.
Solution Approach 2:
The frame structure is designed to change its physical parameters (shape, volume) through controlled deformation at the deformation section. This parameter change capability allows the frame to adapt to swelling of battery cells, maintaining structural integrity and protecting welding joints from stress-induced failure during long-term operation.
3Strength
If the frame structure is rigid to maintain structural integrity, then the frame provides strong support, but the welding parts are more susceptible to rupture during assembly and swelling
Solution Approach 1:
The frame is segmented into different functional sections: rigid sections that provide structural support and strength, and a flexible deformation section that manages stress. This segmentation allows the frame to maintain overall strength while localizing flexibility at the deformation section to protect welding parts from stress concentration during assembly and swelling.
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 effectively prevents the rupture of welding parts during assembly and due to swelling, ensuring the battery module remains functional and non-defective, thus implementing remarkably excellent concept products.
Implementation Method 1
a cooling plate coupled to one surface of the bottom plate at one side of the bottom plate
Data Source
AI summary
The battery module according to the present disclosure includes a cell block assembly including a plurality of cells, a bottom plate disposed on a first surface of the cell block assembly, a frame surrounding a second surface opposite to the first surface and a side surface of the cell block assembly, and a pair of end plates disposed on each of front and rear surfaces of the cell block assembly, respectively.