Battery Module Structural Integrity via Force Redistribution
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Solution Overview
Problem
Traditional battery modules lack structural rigidity, making them vulnerable to external forces such as uneven terrain and unintentional impingements, which can cause damage and wear on electronic components.
Innovation Solution
A battery module design featuring a housing with a skeletal frame and framework that aligns with the skeletal frame to absorb and redirect external forces, providing structural support and protection to the electrochemical cells, while also incorporating rigidity features like truss-like members to increase structural rigidity without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery module design is used, then device complexity is low, but structural rigidity and protection against external forces are insufficient
Solution Approach 1:
The battery module structure is segmented into distinct functional components: a skeletal frame providing structural support, a framework for force redistribution, and a housing for component containment. This segmentation allows each component to be optimized for its specific function while collectively achieving high structural rigidity without excessive overall complexity.
Solution Approach 2:
The patent employs composite structural design combining the skeletal frame and framework in an integrated assembly. This composite approach creates a synergistic structure where the frame and framework work together to provide enhanced structural rigidity and force distribution capabilities beyond what either component could achieve alone.
2Strength
If reinforced structural components are added to battery modules, then structural rigidity improves, but weight increases
Solution Approach 1:
By segmenting the structural support function across multiple lightweight components (skeletal frame, framework, housing) rather than using a single heavy reinforcement, the design achieves necessary structural rigidity while minimizing overall weight increase. Each segment can be optimized for strength-to-weight ratio.
Solution Approach 2:
The framework acts as an intermediary structure between the skeletal frame and the electrochemical cells, distributing external forces across the entire assembly rather than concentrating stress on single heavy components. This intermediary structure enables lightweight design while maintaining structural integrity.
3Object-affected harmful factors
If simple housing structure is used, then ease of manufacture is high, but protection against external forces is insufficient
Solution Approach 1:
The protective structure is segmented into the skeletal frame, framework, and housing components, each manufactured separately and then assembled. This segmentation allows each component to be optimized for its specific protective function while maintaining manufacturing simplicity through modular construction and standard joining methods.
Data Source
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Figure 3
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AI summary
A battery module includes a housing configured to receive a plurality of electrochemical cells, a skeletal frame coupled with the housing, and a framework disposed proximate to the skeletal frame. Moreover, the framework is substantially aligned with the skeletal frame and configured to transfer a force applied to the framework to the skeletal frame.