Battery Module Frame Fastening to Resist Cell Swelling Deformation
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Solution Overview
Problem
Conventional battery modules face challenges in assemblability due to complex welding processes, high probability of welding defects, and limited material diversity, as well as structural instability from cell swelling, which affects the rigidity and stability of the module.
Innovation Solution
A battery module design featuring a module frame with screw coupling parts and protrusion-shaped fixing parts that secure the end and upper plates, minimizing welding defects and deformation during cell swelling, thereby enhancing assemblability and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to assemble the module frame components, then the structural strength is improved, but the assemblability deteriorates due to complex welding processes and high probability of welding defects
Solution Approach 1:
The patent replaces the welding process with a mechanical fastening system using fastening members (screws or clips) that engage with recesses in the frame components. This substitution eliminates complex welding operations while maintaining structural integrity through precise mechanical interlocking, thereby improving assemblability without sacrificing strength.
Solution Approach 2:
The patent introduces fastening members as intermediary elements between frame components (end plates, upper plates, side plates). These fastening members serve as mediators that join components together through threading or clipping mechanisms, avoiding direct welding between frame parts while achieving reliable structural connections.
2Stability of the object's composition
If multiple welding lines are used to connect frame structures, then the structural stability is improved, but the manufacturing complexity increases due to difficulty of welding processability
Solution Approach 1:
The patent segments the joining function into discrete fastening members that can be independently installed at specific locations. Instead of continuous welding lines connecting multiple frame components, separate fastening members are used at critical joints, simplifying the manufacturing process while maintaining structural stability through distributed fastening points.
3Strength
If welding is used to join frame components, then the structural rigidity is improved, but the material diversity is limited as welded materials must be the same
Solution Approach 1:
The patent employs fastening members that serve as universal connectors capable of joining different material types (metal, plastic, composite). The fastening mechanism (threaded holes or recesses) can accommodate various materials without requiring material compatibility for welding, thereby enabling material diversity while maintaining structural rigidity through the mechanical fastening system.
4Device complexity
If the module frame lacks anti-deformation structure, then the manufacturing simplicity is maintained, but the structural stability deteriorates when cell swelling occurs
Solution Approach 1:
The patent incorporates anti-deformation structures (protrusions and recesses) in the frame components that preemptively counteract the swelling force of battery cells. These structures are designed in advance to engage with swollen cells, preventing deformation of the module frame before it occurs, thereby maintaining structural stability without complicating manufacturing.
Data Source
AI summary
A battery module according to an embodiment of the present disclosure includes: a cell assembly including a battery cell stack in which a plurality of battery cells are stacked; a module frame that wraps the cell assembly; and end plates that cover the front and rear surfaces of the cell assembly opened in the module frame. The module frame comprises a frame member which covers a lower part and both side surfaces of the cell assembly, and an upper plate that covers an upper part of the cell assembly. A first fixing part is formed at an edge of the frame member coupled with the end plate.