Battery Module Housing Side Panel Composite Design
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Solution Overview
Problem
Conventional battery module housings face challenges in meeting high mechanical requirements while being safe and efficient, with heavy metal components and the need for additional insulation posing risks of short circuits and weight issues.
Innovation Solution
A module housing design featuring side panels with a base frame made from electrically insulating material and a metal strip that extends along the longitudinal direction, providing mechanical stability and electrical insulation without the need for separate insulating films, allowing for weight savings and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If side panels are made from metal to meet high mechanical requirements, then strength and stability are improved, but weight increases and electrical insulation risks arise
Solution Approach 1:
The side panel is constructed as a composite structure combining a plastic base frame (providing electrical insulation and structural support) with a metal strip (providing mechanical strength). This composite design allows the housing to meet high mechanical requirements while reducing overall weight compared to fully metal construction and providing inherent electrical insulation.
2Reliability
If additional plastic inserts or insulating films are added to provide electrical insulation, then insulation safety is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The electrical insulation function is merged into the base frame structure itself by making the base frame from electrically insulating plastic material. This eliminates the need for separate plastic inserts or insulating films, as the base frame simultaneously provides structural support, mechanical strength (when combined with metal strip), and electrical insulation in a single integrated component.
3Stability of the object's composition
If conventional metal side panels are used, then mechanical stability is improved, but weight increases and short circuit risks arise
Solution Approach 1:
The side panel uses a composite construction with a plastic base frame providing electrical insulation that prevents short circuits, while a metal strip attached to the base frame provides the necessary mechanical stability. This composite approach simultaneously addresses both requirements without the harmful effects of using metal alone.
Data Source
AI summary
A module housing for a battery module for receiving a cell stack with several battery cells arranged adjacently in a stacking direction. The module housing has a first end panel unit and a second end panel unit for delimiting the cell stack on either side in the stacking direction, and two side panel units, each having a side panel. The first and second end panel units and the two side panel units are arranged relative to one another, such that they enclose a receiving area for receiving the cell stack. The side panel thus includes a base frame, which is formed from an electrically insulating material, and which directly connects the receiving area, and a metal strip, which extends at least over a total length of the receiving area in a longitudinal direction, and which does not adjoins the receiving area.