Battery Module Guide Frame for Heat Isolation and Mold Release
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Solution Overview
Problem
Conventional battery modules face issues with high defect rates during manufacturing due to frame damage and inefficient heat transfer between cylindrical battery cells, leading to potential secondary damage such as fires.
Innovation Solution
A battery module design featuring a frame assembly with guide portions and a foam material having low thermal conductivity, along with a manufacturing method that uses a mold unit with support rods to minimize frame damage and enhance heat insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a foam material is injected into the mold and hardened to form the frame, then the frame can be manufactured, but the frame may be damaged due to weak physical properties of the thin portions between receiving holes
Solution Approach 1:
The frame is divided into a frame body and separate guide portions. The guide portions are pre-formed components that are inserted into the frame body after the frame body is separated from the mold. This segmentation allows the frame body to be manufactured without the weakness issue, while the guide portions provide the necessary structural support and guidance functions.
Solution Approach 2:
The guide portions are extracted as separate components from the frame manufacturing process. Instead of forming the guide portions directly in the mold with the frame body, they are manufactured separately and then inserted into the frame body. This extraction resolves the strength issue by allowing the guide portions to be made from materials with better mechanical properties.
2Reliability
If an assembly type battery module is used, then the battery cells can be held and protected, but a lot of time is taken to manufacture the battery module
Solution Approach 1:
The guide portions are inserted into the frame body to form an integrated frame assembly that combines the holding function of the frame body with the guidance function of the guide portions. This merging creates a unified structure that provides both protection and precise positioning, improving manufacturing efficiency while maintaining reliability.
Solution Approach 2:
The guide portions are prepared in advance as pre-formed components before being inserted into the frame body. This preliminary preparation allows for efficient assembly, as the guide portions are already manufactured to precise specifications, reducing the time required during the final assembly process while ensuring proper positioning and protection of battery cells.
3Ease of manufacture
If the frame has thin portions between receiving holes, then the frame can be manufactured using mold injection, but heat transfer between battery cells cannot be interrupted
Solution Approach 1:
The guide portions act as intermediary components between the frame body and the battery cells. These guide portions are made of materials with low thermal conductivity, serving as thermal barriers that interrupt heat transfer between adjacent battery cells while still allowing the frame to be manufactured using conventional mold injection processes for the frame body.
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 reduces frame damage during separation from the mold and inhibits heat transfer, thereby minimizing defects and preventing secondary damage like fires.
Implementation Method 1
a foam material is injected into the mold and is hardened to form the frame
Implementation Method 2
a foam material having flame retardancy or a foam material having low thermal conductivity
Data Source
AI summary
A battery module having a guide frame and a method of manufacturing the same are provided. The battery module including a plurality of cylindrical battery cells; a frame assembly configured to receive the cylindrical battery cells; and a module case configured to wrap the cylindrical battery cells and the frame assembly. The frame assembly includes a frame body having first receiving holes therein; and guide portions in the first receiving holes.