Battery Module Frame Stepping to Cut Resin Gaps
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Solution Overview
Problem
Existing battery modules face challenges in maximizing space utilization and minimizing the use of thermal conductive resin due to structural design limitations, leading to unnecessary gaps and increased material usage.
Innovation Solution
The battery module design incorporates a frame member with a stepped or modified bottom portion that reduces gaps through press-molding, featuring protrusions or concave-convex structures to minimize thermal conductive resin usage and enhance structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery modules are tightly fixed in the battery pack, then structural stability is improved, but stress concentration and deformation occur during thermal expansion and contraction
Solution Approach 1:
The support structure is divided into multiple support pieces distributed across the battery pack, with each support piece independently supporting battery modules. This segmentation allows localized adaptation to thermal expansion while maintaining overall structural stability.
Solution Approach 2:
Different regions of the battery pack are provided with support pieces at different positions, creating non-uniform local support characteristics. This allows the structure to accommodate differential thermal expansion at different locations while maintaining overall stability.
2Temperature
If battery modules are loosely arranged in the battery pack, then thermal expansion and contraction are accommodated, but structural stability and electrical connection reliability deteriorate
Solution Approach 1:
Support pieces are pre-installed at specific positions before battery modules are placed, creating predetermined support points that guide proper module placement. This ensures both thermal expansion accommodation and reliable electrical connections are achieved through correct positioning.
Solution Approach 2:
Support pieces act as intermediary elements between the battery pack structure and battery modules, mediating the interaction by providing both mechanical support for stability and proper positioning for electrical connection reliability while allowing thermal movement.
3Manufacturing precision
If support pieces are positioned precisely, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Battery modules themselves serve as positioning references for placing support pieces, using the modules' own geometry and features to determine support piece locations. This self-positioning approach achieves precise positioning without requiring complex external positioning systems.
Solution Approach 2:
Support pieces are designed with universal features that allow them to be positioned and secured using the same methods regardless of their specific location in the battery pack. This multi-functionality reduces the need for location-specific customization, simplifying the overall device complexity while maintaining positioning precision.
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked, a frame member for housing the battery cell stack and having an opened upper portion, and an upper plate for covering the battery cell stack on an upper portion of the frame member, wherein a stepped portion is formed at the bottom portion of the frame member corresponding to the upper plate, the stepped portion is formed in each of both end portions and between both end portions with respect to the longitudinal direction of the battery cell, and wherein the stepped portion is formed by a bending section of the bottom portion of the frame member.