Battery Module Housing Assembly to Prevent Bending
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Solution Overview
Problem
The manufacturing of battery systems is cumbersome and cost-intensive, and existing battery module housings are limited by mechanical resilience issues, leading to bending during operation and reduced service life due to heat-induced expansion of battery cells.
Innovation Solution
A battery module design featuring a housing with a bottom, top, and side portions, allowing orthogonal insertion of a battery cell stack, with exposed electrode terminals and venting valves, and incorporating compressible elastic elements and a cooling plate to enhance rigidity and facilitate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a conventional battery module housing is used to accommodate battery cells, then the housing can be assembled with battery cells, but the housing bends during operation due to heat-induced expansion, reducing service life
Solution Approach 1:
The housing is divided into a modular assembly comprising a base portion, a top portion, and side portions that can be separately manufactured and then assembled together. This segmentation allows each component to be optimized independently and facilitates thermal expansion accommodation through the modular joint design, preventing housing bending while maintaining structural integrity throughout the battery module's service life.
2Ease of manufacture
If battery cells are inserted into the housing in the conventional manner, then the assembly can be completed, but the manufacturing process is cumbersome and cost-intensive
Solution Approach 1:
The housing components (base portion, top portion, side portions) are pre-assembled into a complete housing structure before battery cell insertion. This preliminary assembly of the housing framework simplifies the subsequent battery cell installation process, reduces manufacturing steps, and increases overall production efficiency while maintaining ease of manufacture.
3Strength
If the housing structure is reinforced to prevent bending, then structural integrity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The housing employs a composite construction using aluminum alloy materials that provide high strength-to-weight ratio and inherent rigidity. This composite approach achieves the required housing rigidity to prevent bending while avoiding excessive structural complexity, as the material properties themselves contribute to structural strength rather than requiring additional reinforcing elements.
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 prevents bending of the housing, improves assembly efficiency, and extends the service life of the battery module by maintaining structural integrity and facilitating heat dissipation.
Implementation Method 1
incorporating compressible elastic elements and a cooling plate to enhance rigidity
Implementation Method 2
incorporating compressible elastic elements and a cooling plate to enhance rigidity and facilitate assembly
Data Source
AI summary
A battery module including a battery cell stack including a plurality of battery cells arranged in a stacking direction and a housing configured to accommodate the battery cell stack. The housing includes a bottom portion; a top portion; two side portions arranged opposite to each other in the stacking direction and interconnecting the bottom portion and the top portion in a height direction; and a side opening through which the battery cell stack is insertable into the housing in an insertion direction, the insertion direction being orthogonal to the stacking direction and being orthogonal to the height direction. The top portion includes an opened section overlaying the electrode terminals and the venting valves of the plurality of battery cells of the battery cell stack when the battery cell stack is accommodated in the housing.