Battery Module Assembly with Caulking Pipe Binding
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Solution Overview
Problem
Existing battery module assembly technologies face issues with size increase, increased number of elements, and prolonged assembly cycle time due to the use of aluminum materials that are prone to water damage and the rib bending phenomenon during injection processing, which complicates the insertion of cell covers into lower frame members.
Innovation Solution
A battery module assembly design that utilizes a caulking pipe to bind cartridges and cells vertically, eliminating the need for external frame members and integrating voltage sensing assemblies within the cartridges, thereby reducing the overall size, number of elements, and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If aluminum material is used for cell cover to decrease size, then size is reduced, but insulating properties are damaged by water
Solution Approach 1:
The patent uses a composite structure combining aluminum material with an insulating coating layer. The aluminum base material provides mechanical strength and small size, while the insulating coating layer prevents water penetration and maintains electrical insulation properties, thus resolving the contradiction between size reduction and insulating reliability.
2Ease of manufacture
If insert nut structure and insert bolt structure are added for assembly and mounting, then assembly capability is improved, but battery module size increases and number of elements increases
Solution Approach 1:
The patent integrates the mounting structure directly into the lower frame member by forming a mounting protrusion that extends from the frame body. This eliminates the need for separate insert nuts and bolts, combining multiple functions into a single integrated component, thus reducing the number of elements while maintaining assembly capability.
3Productivity
If lower frame member is manufactured by injection process, then manufacturing efficiency is improved, but rib bending phenomenon occurs causing assembly cycle time increase
Solution Approach 1:
The patent incorporates reinforcement ribs directly into the lower frame member during the injection molding process. These pre-formed reinforcement ribs strengthen the partition wall parts before assembly, preventing the bending phenomenon that would otherwise require manual unfolding operations, thus eliminating assembly cycle time delays while maintaining manufacturing efficiency.
Data Source
AI summary
A battery module assembly includes a plurality of cells, a plurality of cartridges including a first cartridge (a cartridge A) and a second cartridge (a cartridge B) alternately stacked with a corresponding cell therebetween, and a caulking pipe inserted into a through hole provided in a corner of each of the stacked plurality of cartridges, for assembling the plurality of cartridges. A bus bar among main elements configuring a voltage sensing assembly is disposed in a frame configuring a short side among four frames configuring the first cartridge, and a sensing wire among the main elements configuring the voltage sensing assembly is disposed in two frames configuring a short side and one frame configuring a long side among four frames configuring the second cartridge.