Battery Module Frame Bent Portions Holder Groove Assembly
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Solution Overview
Problem
Current battery modules face challenges in achieving efficient production and ensuring safety, particularly in diversifying shapes and maintaining high-energy density while preventing unwanted short circuits and mechanical failures.
Innovation Solution
A battery module design featuring a frame with bent portions that are press-fit into a holder's groove, reducing component count and using an elastic member and insulating elements to enhance coupling and safety, while eliminating the need for bolts and nuts for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery module assembly methods are used with bolts and nuts, then structural strength is ensured, but production efficiency decreases and device complexity increases
Solution Approach 1:
The frame integrates multiple structural functions into a single component: it provides structural support, electrical insulation through coating layers, and mechanical fastening through integrated bent portions that engage with holder grooves. This eliminates the need for separate bolts, nuts, and insulating materials, thereby improving production efficiency and reducing assembly complexity while maintaining structural strength
Solution Approach 2:
The bent portions of the frame act as intermediary mechanical features that engage with corresponding grooves in the holder, creating a snap-fit or press-fit connection. This intermediary mechanism replaces traditional threaded fasteners, enabling faster assembly without compromising structural integrity
2Reliability
If more components are used to ensure safety and prevent short circuits, then reliability improves, but device complexity increases
Solution Approach 1:
The frame combines multiple safety functions into a single component: structural support for mechanical strength, insulating coating layers (such as electroplated zinc or polymer coatings) to prevent electrical short circuits, and integrated fastening features. This reduces the total component count while maintaining or improving reliability through multi-functional integration
Solution Approach 2:
The frame employs composite material structures, such as metal base material with insulating coating layers (e.g., electroplated zinc, nickel, or polymer coatings), to simultaneously achieve mechanical strength and electrical insulation. This composite approach prevents short circuits without adding separate insulating components
3Adaptability or versatility
If battery module shape is diversified to meet various applications, then adaptability improves, but manufacturing precision requirements increase
Solution Approach 1:
The battery module design segments the structure into modular components: standardized battery cells, holders with grooves for precise positioning, and frames with bent portions for flexible configuration. This segmentation allows different frame configurations to be assembled around the same standardized cells, enabling shape diversity while maintaining consistent manufacturing precision requirements for each modular component
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
This design improves production efficiency, enhances safety by preventing mechanical failures and short circuits, and allows for more flexible module shapes, addressing the need for diversified battery module applications.
Implementation Method 1
an elastic member between the battery cells and the holder
Implementation Method 2
At least a portion of the first bent portion may be press-fit into the groove
Data Source
AI summary
A battery module includes a plurality of battery cells aligned along one direction, each of the plurality of battery cells including terminals at first surfaces of the battery cells. A holder is on the first surfaces of the battery cells and has a groove. A frame surrounds side surfaces adjacent to the first surfaces of the battery cells and includes a first bent portion that is at least partially inserted into the groove.