Battery Module Casing Separation Prevention via Mechanical Interlock
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Solution Overview
Problem
Battery modules are prone to casing separation due to weakened bonding from defects or time-related issues during welding, leading to potential separation during vibration or impact.
Innovation Solution
A battery module design featuring a substrate protecting body with bent units that contact and limit the movement of the casing, combined with a bushing member and casing to prevent separation, and a battery pack incorporating this module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plates are combined using welding method to protect internal components, then protection strength is improved, but bonding strength weakens due to welding defects or time elapse
Solution Approach 1:
The protective structure is divided into multiple plates (first plate, second plate, third plate) that are combined through bending and physical interference rather than welding. Each plate can be independently formed and assembled, eliminating welding defects while maintaining protective strength.
Solution Approach 2:
Instead of using welding to join plates (conventional approach), the invention uses bending deformation and physical interference (hooks, grooves, protrusions) to achieve plate combination. This inverted approach replaces the weak welded joints with mechanically interlocked structures that prevent separation during vibration or impact.
2Strength
If plates are welded together, then initial bonding is achieved, but separation occurs during vibration or impact due to weakened bonding
Solution Approach 1:
The plate combination structure incorporates dynamic elements such as bent portions, hooks, and grooves that allow controlled movement and deformation. These dynamic features enable the structure to absorb vibration and impact forces while maintaining the overall combination, preventing separation under dynamic conditions.
Solution Approach 2:
The plates are designed with bent portions and flexible configurations that can deform elastically during vibration or impact. This flexibility allows the structure to accommodate dynamic forces without breaking the connection between plates, maintaining combination stability under varying conditions.
3Reliability
If substrate protecting body is exposed, then it can protect cartridge assembly, but it is vulnerable to damage from external forces
Solution Approach 1:
The substrate protecting body is nested within the cartridge assembly structure, which itself is nested within the battery module housing. This multi-layer nesting provides progressive protection, where outer structures shield the substrate protecting body from direct external forces while maintaining its protective function for the cartridge assembly.
Solution Approach 2:
The cartridge assembly and battery module housing are designed as protective enclosures that cushion the substrate protecting body from external impacts before the forces can reach it. This beforehand cushioning reduces the vulnerability of the substrate protecting body to damage from external forces.
Data Source
AI summary
Provided is a battery module. The battery module according to an embodiment of the present disclosure may include: a cartridge assembly including a plurality of cartridges configured to receive battery cells; a substrate protecting body combined to the cartridge assembly; a casing configured to receive the cartridge assembly and the substrate protecting body and surround the cartridge assembly and the substrate protecting body; and a cover capable of being combined to the casing.