Battery Module Frame Rib for Blocking Welding Laser Transmission
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Solution Overview
Problem
During welding of battery modules, laser transmission between frames can potentially damage the battery cells, as conventional structures do not effectively prevent laser penetration.
Innovation Solution
A battery module design featuring a rib protruding from the upper frame, which cuts off laser transmission between the upper and lower frames, with the rib being at least 1.5 mm in height and optionally formed by extrusion or separate attachment, and featuring a rib insertion part and groove for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed between upper and lower frames to assemble battery module, then manufacturing precision and strength are improved, but laser transmission damages battery cells
Solution Approach 1:
A laser blocking member is introduced as an intermediary component between the upper and lower frames during welding. This member selectively blocks laser transmission to prevent damage to battery cells while allowing the welding process to proceed effectively, thus resolving the contradiction between achieving strong frame connection and preventing laser-induced damage.
Solution Approach 2:
The welding structure is segmented by dividing the welding area into multiple zones. Some regions are designated for laser welding while others incorporate laser blocking members that prevent laser transmission. This segmentation allows the welding process to be performed in a controlled manner, maintaining strength while protecting battery cells in specific areas.
2Ease of manufacture
If conventional welding structure is used between frames, then manufacturing simplicity is maintained, but laser transmission occurs causing safety issues
Solution Approach 1:
The laser blocking member serves as a simple intermediary component that can be easily integrated into the existing welding process. It blocks laser transmission to prevent battery cell damage while maintaining the overall simplicity of the manufacturing process, thus resolving the contradiction between ease of manufacture and reliability.
3Productivity
If laser welding is used to join frames quickly, then productivity is improved, but harmful laser transmission damages battery cells
Solution Approach 1:
The laser blocking member is positioned between the upper and lower frames to selectively block laser transmission during high-speed laser welding. This allows productivity to be maintained through efficient laser welding while preventing harmful laser transmission to battery cells, resolving the contradiction between productivity and safety.
Solution Approach 2:
The laser blocking members are strategically positioned only in specific locations where battery cells are present, rather than blocking the entire welding area. This local quality approach allows laser welding to proceed efficiently in non-sensitive areas while protecting battery cells in critical zones, thus maintaining productivity while preventing damage.
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
Prevents laser damage to battery cells by effectively blocking laser transmission between the frames during welding, enhancing the safety and integrity of the battery module and pack.
Implementation Method 1
a rib protruding from the upper frame, which cuts off laser transmission between the upper and lower frames
Data Source
AI summary
A battery module which prevents laser transmission, and a battery pack including the same, comprises: a battery cell stack in which a plurality of battery cells are stacked, a lower frame covering a lower surface and both side surfaces of the battery cell stack, an upper frame covering an upper surface of the battery cell stack, and a rib protruding from the upper frame so as to align with a pad located between an outermost battery cell of the battery cell stack and one of the side surfaces of the lower frame. The rib is configured to cut off a laser transmitted between the upper frame and the lower frame.