Battery Module Frame Assembly Without Welding for Better Insulation

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Solution Overview

Problem

Existing battery modules face challenges in securing adequate insulation performance due to heat damage during the welding process, which limits the attachment region of insulating sheets and buffer pads, compromising their effectiveness.

Innovation Solution

A battery module design that connects frames without welding, using a U-shaped frame and an upper plate coupled by rivets or hooks, allowing the insulating sheet and buffer pad to extend to the connection region, thereby maximizing their formation area and ensuring sufficient insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to couple the U-shaped frame and upper plate, then the connection strength is improved, but the insulating sheet and buffer pad are damaged by heat

Engineering Contradiction:

Improveconnection strengthVSAvoidheat damage to insulating materials

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the welding process (thermal connection method) with a mechanical connection method using connection portions that physically couple the U-shaped frame and upper plate without generating heat. This substitution eliminates heat damage to insulating materials while maintaining structural connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces connection portions as intermediary elements between the U-shaped frame and upper plate. These connection portions serve as mediators that provide mechanical coupling without direct welding contact, thereby protecting insulating materials from heat exposure while ensuring structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the insulating sheet attachment region is limited to avoid heat damage, then the insulating materials are protected, but the insulation performance is insufficient

Engineering Contradiction:

Improveprotection from heat damageVSAvoidinsulation performance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

By replacing welding with mechanical connection portions, the patent eliminates the heat-affected zone, allowing the insulating sheet to be attached across the entire surface area including regions adjacent to the connection portions. This expands the attachment region and ensures comprehensive insulation coverage without heat damage risks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If welding is used for frame connection, then the manufacturing process is simplified, but the buffer pad region is limited and insulation cannot be secured

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidinsulation coverage

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces welding with mechanical connection portions, which similarly simplify the manufacturing process by providing a straightforward assembly method. However, this substitution enables the buffer pad and insulating sheet to extend to the connection portion regions, ensuring comprehensive insulation coverage that was previously unachievable with welding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20230291060A1Battery module and battery pack including the same

Publication Date: 2023.09.14 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a battery cell stack in which a plurality of battery cells are stacked, a first frame member accommodating the battery cell stack and having an open upper portion, a second frame member covering the battery cell stack from an upper portion of the first frame member, a connection portion coupling the first frame member and the second frame member to each other, and an insulating sheet disposed between the battery cell stack and the second frame member, wherein the insulating sheet is disposed to extend up to a region in which the connection portion is positioned.