Battery Frame Segmentation for Cooling Plate Shrinkage Control
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Solution Overview
Problem
Existing frames for secondary batteries suffer from deformation and distortion of cooling plates due to shrinkage during manufacturing, leading to unstable cooling channels and dimensional changes, which affects the performance and stacking of battery modules.
Innovation Solution
A frame structure with a main frame composed of multiple unit frames and a cooling plate made of aluminum, where the main frame is injection-molded around the cooling plate, distributing shrinkage evenly to prevent deformation and maintaining a stable cooling channel and surface contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the main frame is injection-molded as a single piece around the cooling plate, then the manufacturing process is simple and efficient, but the shrinkage during cooling causes deformation and distortion of the cooling plate
Solution Approach 1:
The main frame is divided into multiple independent unit frames (first, second, third, and fourth unit frames) that are separately injection-molded and then assembled. This segmentation distributes the shrinkage stress during cooling, preventing concentrated deformation on the cooling plate while maintaining manufacturing efficiency through modular production.
2Temperature
If the cooling plate is made thin to reduce weight and improve heat dissipation, then the cooling performance is enhanced, but the cooling plate becomes more susceptible to deformation during manufacturing
Solution Approach 1:
By dividing the main frame into multiple unit frames, the shrinkage force is distributed across multiple attachment points rather than concentrated on a single location. This allows the cooling plate to be made thinner for better heat dissipation while the distributed support structure prevents deformation during the cooling process.
Solution Approach 2:
The unit frames are strategically positioned at specific locations around the cooling plate, providing localized support where shrinkage forces are most likely to cause deformation. This allows the cooling plate to maintain thin sections for optimal thermal performance while having reinforced support at critical locations.
3Strength
If the frame body is made with high rigidity to maintain structural integrity, then the mechanical strength is improved, but the shrinkage during cooling process causes greater stress and deformation on attached components
Solution Approach 1:
The rigid frame structure is segmented into multiple unit frames that are assembled together. Each unit frame can shrink independently during cooling, and the modular assembly allows for stress distribution, maintaining overall structural integrity while reducing localized deformation stress on the cooling plate.
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
This design ensures stable cooling performance, prevents deformation of the cooling plate, and allows for easy stacking and consistent dimensions of battery modules, enhancing the reliability and efficiency of the battery module assembly.
Implementation Method 1
an external air may be allowed to flow around the cooling plate 20 to lower the temperature of secondary batteries by means of heat exchange between the cooling plate 20 and the air
Implementation Method 2
the frame body 10 subject to injection molding may be relatively greatly shrunken in comparison to the cooling plate 20
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed is a frame for a secondary battery, which has an improved structure to prevent a cooling plate from being deformed or distorted due to shrinkage of a main frame. The frame for a secondary battery includes a cooling plate made of a thermally conductive material with a plate shape, and a main frame having a plurality of unit frames spaced apart from each other in a horizontal direction by a predetermined distance, the main frame being configured to surround a rim of the cooling plate and made of a material different from the cooling plate.