Battery Module Frame Coupling for Impact-Stable Assembly
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Solution Overview
Problem
Existing battery modules suffer from instability due to weak coupling between cell frames, leading to gaps and potential short circuits during external impacts or vibrations, and require cumbersome assembly processes with screw bolts.
Innovation Solution
A battery module design featuring first and second cell frames with fixing bars and long bolts to limit movement, covered by first and second covers, and a middle case with inward protruding coupling ribs for enhanced stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple screw bolts are used to couple cell frames, then coupling strength is improved, but assembly time increases
Solution Approach 1:
The coupling mechanism is segmented into modular components: cell frames with integrated coupling protrusions, separate coupling arms, and connecting bolts. This allows pre-assembly of frame components and simplifies the final coupling operation, reducing assembly time while maintaining strength
Solution Approach 2:
Coupling arms serve as intermediary elements between cell frames, providing a mechanical leverage system that enables strong coupling with fewer fastening points. The arms distribute mechanical loads across multiple contact points, achieving high coupling strength with reduced bolt count
2Loss of time
If fewer screw bolts are used to couple cell frames, then assembly time is reduced, but coupling strength decreases
Solution Approach 1:
The cell frames are designed with pre-formed coupling protrusions and recesses that align automatically during assembly. This preliminary geometric configuration ensures proper positioning before fastening, allowing fewer bolts to achieve adequate coupling strength without requiring multiple alignment adjustments
Solution Approach 2:
The coupling structure combines rigid cell frame materials with flexible coupling arms, creating a composite system that distributes mechanical stresses. This material combination allows the use of fewer fasteners while maintaining overall coupling strength through the synergistic behavior of different components
3Ease of manufacture
If cell frames are loosely coupled, then assembly is simpler, but stability during external impacts deteriorates
Solution Approach 1:
The coupling system incorporates controlled flexibility through the coupling arms, which can elastically deform to absorb impact energy while maintaining connection. This dynamic response allows the structure to withstand external impacts without rigid failure, preserving stability while keeping the assembly process simple
4Reliability
If cell frames are tightly coupled, then stability during external impacts is improved, but assembly complexity increases
Solution Approach 1:
The coupling function is extracted from the cell frame body into separate, dedicated coupling arms and protrusions. This separation allows the main frame structure to remain simple while the specialized coupling components provide the necessary stability, reducing overall assembly complexity
Data Source
AI summary
A battery module includes a plurality of battery cells, a first cell frame and a second cell frame disposed at front and rear sides, respectively, and coupled to each other to define an internal space in which the plurality of battery cells is disposed, and having a hole of a predetermined size, a plurality of fixing bars, each disposed in each of a front surface of the first cell frame and a rear surface of the second cell frame and configured to limit front-rear movement of the first and second cell frames, and at least one long bolt inserted into the hole, and having a front end part coupled to the fixing bar disposed in the front surface of the first cell frame and a rear end part coupled to the fixing bar disposed in the rear surface of the second cell frame.