Integrated Battery Module Housing With Impact-Absorbing Cell Stack Support
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Solution Overview
Problem
Current battery modules for high-power applications, such as electric vehicles, are complex, costly, and heavy due to the need for multiple components and separate module frames, which complicates manufacturing and increases weight and production time.
Innovation Solution
A battery module design featuring a cell stack with multiple unit cells aligned in a specific direction, surrounded by an insulating member, and housed within a module housing with integral receiving parts, separation walls, and end walls that form impact-absorbing spaces, eliminating the need for a separate module frame and simplifying assembly, while incorporating a cooling channel for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a separate module frame is used to support cell stacks, then structural stability is improved, but device complexity and weight increase
Solution Approach 1:
The module housing integrates both the support frame function and the outer casing function into a single unified structure. The housing directly supports the cell stacks without requiring a separate module frame, thereby reducing component count and structural complexity while maintaining structural stability.
Solution Approach 2:
The module housing serves multiple functions simultaneously: it acts as the outer protective casing, the structural support frame for mounting cell stacks, and the housing for containing cooling channels. This multi-functionality eliminates the need for separate dedicated support structures.
2Manufacturing precision
If multiple separate components are used in module assembly, then manufacturing precision is improved, but manufacturing time and productivity are reduced
Solution Approach 1:
The module housing is designed as an integrated structure that combines the support frame and outer casing into one piece, reducing the number of assembly steps and fastening operations required while maintaining precise positioning of cell stacks.
Solution Approach 2:
The module housing is pre-designed with integrated mounting features and receiving structures that automatically position cell stacks during assembly, eliminating the need for complex alignment procedures and multiple assembly steps.
3Strength
If a separate module frame is used, then structural support is improved, but weight increases
Solution Approach 1:
The module housing integrates the support frame function into the outer casing structure, eliminating the need for a separate heavy support frame while maintaining adequate structural support for the cell stacks.
Solution Approach 2:
The housing structure performs multiple functions including protection, support, and thermal management housing, thereby eliminating redundant structural components and reducing overall weight.
4Reliability
If complex module structures are used, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The integrated module housing reduces the number of parts and assembly operations required, lowering manufacturing complexity and cost while maintaining reliable structural support and protection for the battery cells.
Data Source
AI summary
A battery module includes a cell stack in which a plurality of unit cells are aligned in a first direction and including an insulating member surrounding the plurality of unit cells; and a module housing in which a plurality of receiving parts into which the cell stack is inserted are provided, wherein the receiving part includes a fixing wall surrounding the cell stack and having at least a portion which is in contact with the cell stack.