Battery Module Central Wall for Thermal Isolation and Rigid Assembly
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Solution Overview
Problem
The conventional process of manufacturing long battery modules by assembling individually manufactured sub-modules is complex due to the varying structures of each sub-module, leading to increased manufacturing complexity and inefficiency.
Innovation Solution
A battery module design featuring a central wall connected to side covers to enhance mechanical rigidity and prevent heat propagation between sub-modules, with all sub-modules having the same structure for simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individually manufactured sub-modules are assembled side by side, then the battery module can be manufactured, but the manufacturing process becomes complicated
Solution Approach 1:
The battery module is divided into multiple identical sub-modules, each comprising a cell stack and a busbar frame. This segmentation allows each sub-module to be manufactured independently using the same standardized process, then assembled together to form the complete battery module, thereby simplifying the overall manufacturing process.
Solution Approach 2:
Each sub-module is designed with a universal structure that can serve multiple functions: electrical connection through the busbar frame, mechanical support for the cell stack, and integration with adjacent sub-modules. This universality eliminates the need for different manufacturing processes for different sub-modules.
2Adaptability or versatility
If sub-modules are manufactured individually with different structures, then specific functional requirements can be met, but the overall manufacturing process becomes complicated
Solution Approach 1:
The busbar frame is designed as a universal component that performs multiple functions: electrical connection, mechanical support, and structural integration. This multi-functional design allows a single standardized manufacturing process to produce sub-modules that meet all functional requirements.
Solution Approach 2:
Multiple functions are merged into the busbar frame structure, which simultaneously provides electrical connectivity, mechanical support for the cell stack, and integration interfaces for adjacent sub-modules. This merging eliminates the need for separate components and simplifies the manufacturing process.
3Volume of stationary object
If sub-modules are disposed side by side without thermal isolation, then space is optimized, but heat can propagate to adjacent sub-modules
Solution Approach 1:
Thermal isolation features are extracted and integrated into the busbar frame structure, which separates the heat paths between adjacent sub-modules while maintaining their close proximity for space efficiency. This extraction of thermal management functionality into the structural component solves the heat propagation issue without sacrificing space utilization.
Data Source
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AI summary
A battery module is provided, the battery module including: a first sub-module and a second sub-module respectively including a cell stack in which a plurality of battery cells are stacked; and a central wall disposed between the first sub-module and the second sub-module, wherein the central wall includes a first central wall facing the first sub-module and a second central wall facing the second sub-module, wherein the first central wall has a rotationary symmetrical shape of the second central wall around a first axis.