Battery Module Case With Bumper Structure for Impact Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in protecting internal components from external impact and suffer from increased manufacturing costs due to complex and time-consuming assembly processes.
Innovation Solution
A battery module design featuring a module case with a bumper portion to absorb external impacts, a bus bar positioned in a separation space to prevent electrical contact, and an external housing with a guide rail and projection portion to facilitate easy assembly, reducing the risk of internal damage and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external housing made of metal material is used to protect secondary batteries from external impact, then protection capability is improved, but the housing deforms under impact and causes internal damage or short circuits
Solution Approach 1:
The patent employs a composite structure combining a metal external housing with a polymer foam buffer material. The metal housing provides structural strength and impact resistance, while the foam buffer absorbs impact energy through deformation, preventing force transmission to internal components. This composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent incorporates a buffer portion made of polymer foam material between the metal housing and internal components (module case, bus bar, secondary batteries). This buffer is pre-installed to absorb impact energy before it reaches sensitive internal components, preventing deformation-induced damage and short circuits while maintaining the protective function of the metal housing.
2Device complexity
If the module case is inserted into the external housing without guidance structures, then device complexity is reduced, but damage to internal components occurs during insertion
Solution Approach 1:
The patent introduces guide rails as intermediary structures on the inner wall of the external housing and corresponding guide grooves on the module case. These guide structures mediate the insertion process, aligning the module case with the housing and preventing misalignment or collision that could damage internal components, while adding minimal structural complexity.
3Ease of manufacture
If the insertion process is performed without guidance structures, then manufacturing process is simplified, but insertion time increases due to difficulty and repositioning
Solution Approach 1:
The guide rails and guide grooves act as intermediaries that facilitate smooth and accurate insertion of the module case into the external housing. By providing mechanical guidance, these structures eliminate the need for manual alignment and repositioning, reducing insertion time and improving productivity while maintaining process simplicity.
4Volume of moving object
If the bus bar is positioned close to the outer wall of the module case, then device volume is reduced, but electrical contact with external housing occurs under impact
Solution Approach 1:
The patent positions the bus bar within the module case rather than attaching it directly to the outer wall, creating an internal separation space. The module case itself acts as an intermediary insulating barrier between the bus bar and the external metal housing, preventing electrical contact and short circuits even under impact conditions, while minimizing volume increase.
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 solution effectively absorbs external impacts, prevents electrical leakage, and simplifies the assembly process, enhancing the stability and manufacturing efficiency of the battery module while reducing the risk of accidents like explosions or fires.
Implementation Method 1
a bumper portion protruding from an outer surface of the outer wall in an outer direction to absorb an external impact
Data Source
AI summary
A battery module that effectively protects internal components from external impact and increases manufacturing efficiency is disclosed. The battery module includes a plurality of can type secondary batteries arranged to be laid down in a horizontal direction; a bus bar at least partially formed of an electrically conductive material to electrically connect the plurality of can type secondary batteries; and a module case in which an inner space is formed to accommodate the plurality of can type secondary batteries, and comprising an outer wall formed to surround the inner space and a bumper portion configured to protrude from an outer surface of the outer wall in an outer direction to absorb an external impact.