Battery Module Frame Assembly for Protection and Heat Dissipation
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Solution Overview
Problem
Existing battery module assembly methods result in increased costs, risk of damage from excess load, and inadequate heat dissipation due to complex bracket configurations and lack of comprehensive edge protection.
Innovation Solution
A frame structure assembly kit comprising a bottom frame structure, top frame structure, and pillars forms a rectangular housing that accommodates battery units, providing robust protection, efficient heat dissipation, and reduced weight without applying excess load, using a grid or ladder design with guides for precise positioning and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brackets are used to protect battery stacks, then protection against damage is improved, but the number of connectors and assembly processes increases, resulting in increased costs
Solution Approach 1:
The patent combines the protective function and the structural support function into a single integrated frame structure. The frame serves both as protection for the battery stacks and as the structural skeleton of the battery assembly, eliminating the need for separate brackets and connectors for each stack group.
Solution Approach 2:
The frame structure performs multiple functions simultaneously: it provides mechanical protection for battery stacks, serves as the structural framework, enables heat dissipation through its open design, and provides mounting positions for electrical connectors. This multi-functionality reduces the overall number of components needed.
2Strength
If first bracket and second bracket are not in direct contact, then torsion resistance is improved, but interposition of battery stacks between brackets applies excess load to battery stacks, resulting in high risk of damage
Solution Approach 1:
The patent introduces cushioning members as intermediaries between the frame and the battery stacks. These cushioning members act as a buffer that protects the battery stacks from excess load while maintaining the structural integrity and torsion resistance of the frame structure.
Solution Approach 2:
The cushioning members are pre-installed between the frame and the battery stacks to provide beforehand protection. This prior cushioning prevents excess load from being transmitted to the battery stacks during assembly and operation, thereby reducing the risk of damage while maintaining structural strength.
3Reliability
If entire surfaces of battery stacks are covered with brackets, then protection is improved, but weight of battery assembly increases
Solution Approach 1:
The frame structure provides protection at critical locations (edges and corners of battery stacks) rather than covering entire surfaces. This localized protection approach maintains adequate protection while minimizing the amount of protective material and overall weight of the assembly.
Solution Approach 2:
The frame structure uses thin-walled but structurally optimized profiles that provide adequate protection with minimal material. The open framework design provides necessary protection while keeping the overall structure lightweight compared to solid bracket covers.
4Reliability
If many connectors and assembly processes are used, then protection and structural integrity are improved, but manufacturing costs increase
Solution Approach 1:
The patent combines multiple functions (protection, structural support, heat dissipation, and connector mounting) into a single integrated frame structure, reducing the number of separate components and assembly steps required while maintaining structural integrity.
Solution Approach 2:
The frame structure serves multiple purposes simultaneously, reducing the total number of components needed. By making the frame multi-functional, the patent reduces manufacturing complexity and costs while maintaining or improving structural integrity compared to using separate specialized components.
Data Source
AI summary
A frame structure assembly kit is provided. The frame structure assembly kit includes: a bottom frame structure including a plurality of longitudinal bottom frames and a plurality of lateral bottom frames assembled into a grid or ladder, wherein a part of the longitudinal bottom frames and/or the lateral bottom frames bends or extends upward to form at least one guide for determining the position of each battery unit; a top frame structure including a plurality of top longitudinal frames and a plurality of top lateral frames assembled into a grid or ladder; and a plurality of pillars having a length corresponding to the height of the battery units for connecting four corners of the bottom frame structure to the respective four corners of the top frame structure into a rectangular housing capable of accommodating the battery units.