Battery Module Frame Coupling for Precise End Plate Assembly
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Solution Overview
Problem
Existing battery modules suffer from component deformation and reduced assembly position precision due to the assembly process, which is exacerbated by the use of assembly jigs that cause distortion and alignment deviations.
Innovation Solution
A battery module design that utilizes male-female coupling between the main body frame and end plates, along with specific protrusions and depressions, to ensure precise alignment and minimize deformation during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the frame member is pressed for precise welding, then welding precision is improved, but the frame member deforms due to its small thickness
Solution Approach 1:
The frame member is divided into multiple segments (first frame member, second frame member, third frame member, fourth frame member) that are coupled together through male-female coupling structures. This segmentation allows each segment to be thinner and more flexible while maintaining overall structural integrity, preventing deformation during welding operations.
Solution Approach 2:
Male-female coupling structures act as intermediary elements between frame members, providing precise alignment and positioning. These coupling structures include positioning protrusions and positioning grooves that ensure accurate relative positioning of frame members without requiring excessive pressing force that would cause deformation.
2Ease of manufacture
If assembly is performed with tolerance and jig alignment deviation, then assembly process is simpler, but position precision of components is reduced
Solution Approach 1:
Positioning protrusions and positioning grooves are pre-formed on the frame members during manufacturing. These preliminary positioning features ensure that when assembly occurs, the components automatically align to precise positions without requiring complex jig adjustments or high-precision alignment during the assembly process itself.
Solution Approach 2:
The male-female coupling structures utilize asymmetric geometry (protrusions on one side, grooves on the other) that provide directional guidance and precise positioning. This asymmetric design ensures that components can only be assembled in the correct orientation and position, eliminating alignment deviations caused by jig tolerance.
Data Source
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AI summary
Disclosed is a battery module including a cell assembly including a plurality of battery cells, a main body frame comprising an inner space, wherein the inner space is configured to accommodate the cell assembly, a busbar frame electrically connected to the cell assembly, and an end plate coupled to one side or another of the main body frame, wherein the main body frame and the end plate are coupled to each other by male-female coupling.