Battery Module Frame With Integrated Fastening for Scalable Assembly
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Solution Overview
Problem
Existing battery module assemblies and packs face challenges in cost-effective assembly and manufacturing, often requiring multiple types of parts and complex configurations.
Innovation Solution
A battery module member designed as a frame to enclose and retain battery cells, featuring specific hole configurations for fastening members, allowing for easier assembly and use of fewer part types, thereby simplifying scaling and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple types of parts are used in battery module assemblies, then connection robustness can be improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The battery module member is designed with a universal frame structure that performs multiple functions: it provides structural support, creates cell receptacles through its geometric configuration, and integrates fastening features through the hole pattern. This multi-functionality reduces the number of separate components needed while maintaining connection robustness.
Solution Approach 2:
The frame is segmented into specific regions with holes positioned at strategic locations to create distinct functional zones: cell receptacle areas and fastening areas. This segmentation allows a single component to serve multiple purposes, reducing overall assembly complexity while maintaining reliable connections.
2Strength
If complex configurations are used in battery module assemblies, then connection strength can be improved, but ease of assembly and manufacturing are worsened
Solution Approach 1:
Multiple structural functions are merged into a single battery module member: the frame provides both structural support and cell retention, while integrated holes provide both structural reinforcement and fastening capabilities. This merging simplifies the assembly process by reducing the number of parts that need to be handled and assembled.
Solution Approach 2:
The frame geometry and hole positions are pre-configured during manufacturing to create cell receptacles and fastening features in their final positions. This preliminary action eliminates the need for complex field assembly operations, allowing workers to simply insert cells and fasten components without complex alignment procedures.
3Productivity
If scaling of battery module assemblies is required, then meeting energy demands can be improved, but manufacturing cost and complexity increase
Solution Approach 1:
The universal battery module member design with standardized hole patterns and frame geometry can be used across different assembly sizes. This universality allows linear scaling of battery packs by simply adding more identical module members, maintaining the same manufacturing processes and part inventories regardless of the final energy capacity required.
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
The solution enables efficient assembly and manufacturing of battery module assemblies and packs by using fewer part types, facilitating cost-effective scaling and improving the robustness of connections.
Implementation Method 1
the second hole is configured to receive and retain a fastening member by an interference fit between the fastening member and a second hole inner surface defining the second hole
Data Source
AI summary
The disclosure relates to a battery module member for a battery module assembly for a battery pack, wherein the battery module member has a longitudinal extension in a longitudinal direction, a width extension in a width direction and a height extension in a height direction, and wherein the battery module member is formed as a frame configured to enclose and retain a plurality of battery cells, as seen in a sectional plane defined by the longitudinal direction and the width direction. The disclosure also relates to a battery module assembly, a battery pack and a vehicle.