Battery Module Frame Assembly to Prevent Deformation and Weld Spatter
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Solution Overview
Problem
Existing battery modules face issues with deformation and cracking of frames, reduced cooling performance due to frame thickness, and spatter introduction during welding, which affect productivity and quality, and existing solutions have not adequately addressed these problems.
Innovation Solution
A battery module design featuring a sub frame with a plate shape and a main frame with a U-shaped cross-section, utilizing fitting holes, protrusions, and support parts for stable assembly, along with laser welding through a jig to prevent spatter and improve cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the frame is bent in a 'U' shape to accommodate the cell block, then the structural form is achieved, but the frame experiences deformation and cracking due to applied pressure
Solution Approach 1:
The frame is divided into two separate components: a sub-frame that supports the cell block and a main frame that provides the U-shaped enclosure. This segmentation allows each component to be optimized independently, eliminating the need to bend a single frame which causes deformation and cracking.
Solution Approach 2:
The sub-frame acts as an intermediary component between the cell block and the main frame. It receives the cell block and transfers it to the main frame, distributing the load and preventing direct pressure application that would cause deformation and cracking in a monolithic U-shaped frame.
2Temperature
If the frame thickness is minimized at the portion between the cell block and cooling part to increase cooling performance, then cooling efficiency improves, but the frame thickness is reduced due to processing characteristics
Solution Approach 1:
The frame is segmented into a sub-frame and main frame, allowing the sub-frame to be specifically designed with optimized thickness for cooling performance. The sub-frame can be manufactured with precise thickness control in the region between the cell block and cooling part, independent of the main frame's structural requirements.
Solution Approach 2:
The sub-frame is designed with locally optimized thickness characteristics - thinner in regions requiring heat dissipation to improve cooling performance, and thicker in regions requiring structural strength. This local quality variation is achieved through separate manufacturing of the sub-frame component.
3Strength
If welding is performed on the frame to assemble the battery module, then structural integrity is achieved, but spatter is introduced into the frame during welding
Solution Approach 1:
The frame is divided into sub-frame and main frame components that are welded separately and then assembled. This segmentation allows welding operations to be performed on smaller, more manageable components with better access and control, reducing spatter generation and making it easier to prevent spatter introduction into critical areas.
Solution Approach 2:
The sub-frame serves as an intermediary component that can be pre-assembled with the cell block before being attached to the main frame. This sequencing allows welding to be performed on the sub-frame in a controlled manner, minimizing spatter generation and preventing it from being introduced into the final assembly.
4Ease of operation
If pressure is applied to the frame to forcibly spread the frame walls out during cell block mounting, then the cell block is accommodated, but deformation and cracks occur in the frame
Solution Approach 1:
The frame is segmented into a sub-frame with an opening for cell block insertion and a main frame. The cell block is mounted on the sub-frame first, requiring minimal force to spread, and then the entire assembly is attached to the main frame. This eliminates the need to apply large spreading forces to a monolithic U-shaped frame, preventing deformation and cracking.
Solution Approach 2:
The sub-frame acts as an intermediary that receives the cell block in a low-force operation, then transfers the assembled unit to the main frame. This intermediary structure distributes the mounting forces, preventing the high spreading pressures that would cause deformation and cracking in a single-piece U-shaped frame.
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
The design stabilizes frame dimensions, enhances welding quality, reduces spatter, and improves cooling performance, thereby optimizing production efficiency and reducing defect rates.
Implementation Method 1
welding a point at which the main frame and the sub frame are in contact with each other
Data Source
AI summary
A method for assembling a battery module includes a sub frame providing process of providing a sub frame having a plate shape; a cell block seating process of seating a cell block, in which a plurality of battery cells are coupled to each other, on a top surface of the sub frame; a temporary assembly process of temporarily fixing a main frame having a cross-sectional shape, of which one side is opened, and three surfaces are closed, to the sub frame so that the cell block is accommodated into the inside; and a welding process of welding a point at which the main frame and the sub frame are in contact with each other.