Battery Module Housing Cut-Outs for Cell Bat-Ear Insulation
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Solution Overview
Problem
Existing battery module housings face issues with interference between vulnerable portions of battery cells and the frame, leading to insulation failure and increased separation distances that require thick thermally conductive resin layers, which are costly and inefficient.
Innovation Solution
A battery module housing with a cut-out portion in the frame to accommodate the vulnerable portions, covered by a double injection-molded insulating and thermally conductive synthetic resin, minimizing interference and reducing the thickness of the thermally conductive resin layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the frame is designed without cut-out portions, then the structural integrity and simplicity of the housing is maintained, but the vulnerable portions of battery cells interfere with the frame causing insulation failure and increased separation distances
Solution Approach 1:
The patent applies the extraction principle by removing portions of the frame to create cut-out portions that accommodate the vulnerable portions of battery cells. This extraction eliminates the interference between the frame and vulnerable portions, preventing insulation failure while maintaining structural integrity through the selective removal of non-critical frame sections.
Solution Approach 2:
The frame is segmented into multiple portions with specific cut-out sections removed to create accommodation spaces for the vulnerable portions of battery cells. This segmentation allows the housing to adapt to the battery cell geometry while maintaining the overall structural framework, resolving the conflict between simplicity and insulation reliability.
2Reliability
If the separation distance between battery cell stack and frame is increased to accommodate vulnerable portions, then interference is avoided, but the thickness of the thermally conductive resin layer must be increased which raises production costs
Solution Approach 1:
By extracting portions of the frame to create cut-out portions, the patent eliminates the need for increased separation distance and thick thermally conductive resin layers. The vulnerable portions can directly contact the frame through the cut-out portions, maintaining minimal separation distance while avoiding interference, thus reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The patent replaces the expensive and thick thermally conductive resin layer with a simpler, more cost-effective solution using frame cut-out portions that directly accommodate vulnerable portions. This substitution uses minimal or no additional insulating materials, significantly reducing production costs while maintaining insulation reliability.
3Reliability
If manual insulation tape application process is used, then insulation coverage can be adjusted, but the manufacturing complexity and production time are increased
Solution Approach 1:
The frame cut-out portions are designed to self-accommodate the vulnerable portions of battery cells during the stacking process. This self-service design eliminates the need for manual insulation tape application, as the geometric design of the cut-out portions inherently provides the necessary insulation and positioning, thereby significantly improving manufacturing efficiency and productivity.
Solution Approach 2:
The cut-out portions are pre-designed and pre-formed in the frame structure before battery cell assembly. This preliminary action ensures that the insulation and accommodation functions are already in place, eliminating the need for subsequent manual insulation tape application and streamlining the manufacturing process to improve productivity.
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 minimizes interference, maximizes space utilization, improves insulation, and reduces production costs by eliminating the need for a separate insulation tape application and manual processes.
Implementation Method 1
a double injection-molded portion made of double-injected synthetic resin covers the cut-out portion
Implementation Method 2
it is necessary to thickly form a thermally conductive resin layer provided between the battery cell stack 1 and the frame 2 to assist a cooling action of the battery cell 11
Data Source
AI summary
A housing configured to accommodate a battery cell stack of a battery module is provided. The housing has a frame that includes a cut-out portion formed on an inner surface of the frame adjacent to a protruding-shaped vulnerable portion (bat-ear) provided at a corner portion of each of battery cells included in the battery cell stack. The cut-out avoids interference with the protruding-shaped vulnerable portion. A double injection-molded portion is bonded to a machined surface of the cut-out portion by double injection molding and may have a shape more depressed than the inner surface to cover the cut-out portion while avoiding the interference with the vulnerable portion.