Interlocking Battery Module Case for Heat Dissipation and Cell Stability
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Solution Overview
Problem
Conventional battery modules and packs face challenges in efficiently dissipating heat, stabilizing battery cells, and achieving a compact structure with high energy density and process efficiency.
Innovation Solution
A battery module design featuring a module case with interlocking L-shaped cases and forming grooves to securely hold and efficiently dissipate heat from battery cells, utilizing high thermal conductivity materials and a zigzag bead pattern to prevent interference and ensure stable cell positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional battery modules use simple case structures, then manufacturing is easier, but heat dissipation efficiency is insufficient
Solution Approach 1:
The module case is divided into multiple L-shaped cases that are coupled together through hooking. Each L-shaped case has a horizontal portion and a vertical portion, creating multiple surfaces for heat dissipation. This segmentation increases the total heat dissipation area while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
The L-shaped configuration introduces a vertical dimension to the traditionally horizontal case structure. The vertical portions extend upward from the horizontal portions, creating multiple levels for heat dissipation. This dimensional change allows heat to dissipate from both horizontal and vertical surfaces, significantly improving thermal management efficiency.
2Stability of the object's composition
If battery cells are loosely arranged in the module, then assembly is simpler, but stability and safety are compromised
Solution Approach 1:
The fixing structure is segmented into multiple forming portions, each with first and second forming grooves. These grooves are distributed across the L-shaped cases to engage with different portions of the battery cells. This segmentation provides stable fixation at multiple points without requiring a complex overall structure.
Solution Approach 2:
The forming grooves are strategically positioned at specific locations where they engage with corresponding portions of the battery cells. The first forming grooves engage with edge portions along the longitudinal direction, while the second forming grooves are positioned at both ends to limit movement. This localized engagement provides targeted stability where needed.
3Area of stationary object
If the module case uses a single-piece structure, then manufacturing is simpler, but heat dissipation area is limited
Solution Approach 1:
The module case is constructed from multiple L-shaped cases rather than a single piece. Each L-shaped case can be manufactured independently using standard fabrication processes, then assembled by hooking the horizontal and vertical portions together. This segmentation increases the total heat dissipation area while maintaining ease of manufacture through modular production.
Solution Approach 2:
The L-shaped case design serves multiple functions simultaneously: the horizontal portions provide base support and heat dissipation surfaces, while the vertical portions extend the heat dissipation area upward and provide structural support. The hooking mechanism integrates both structural assembly and thermal management functions into a single design.
4Reliability
If battery cells are allowed to move freely, then assembly is faster, but safety and reliability are reduced
Solution Approach 1:
The forming grooves are pre-formed in the L-shaped cases during manufacturing, creating ready-to-engagement structures that guide battery cell placement. The first forming grooves are prepared to engage edge portions, and the second forming grooves are positioned to limit movement. This preliminary preparation ensures reliable fixation without requiring complex assembly operations.
Solution Approach 2:
The forming grooves are designed to automatically engage with the battery cells when placed in the module. The first forming grooves engage with edge portions along the longitudinal direction, and the second forming grooves at both ends automatically limit cell movement. This self-engaging design provides reliable fixation without requiring additional fastening operations, maintaining assembly speed.
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 dissipates heat, stabilizes battery cells, and achieves a compact structure with high energy density and improved process efficiency, enhancing safety and performance in battery packs and energy storage systems.
Implementation Method 1
utilizing high thermal conductivity materials
Data Source
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AI summary
Disclosed is a battery module, which includes a plurality of battery cells, and a module case configured to accommodate the plurality of battery cells, wherein the module case includes first and second cases coupled to each other by hooking and having shapes corresponding to each other.