Battery Module Frame with Protruding Portions for Film-Covered Cells
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Solution Overview
Problem
Film-covered batteries face issues with reduced volume efficiency and mechanical strength due to varying thicknesses caused by manufacturing variations and electric capacity differences, leading to the need for multiple frame sizes and increased risk of damage from mechanical stress.
Innovation Solution
A battery module design featuring a frame body with protruding portions that match the thickness of the film-covered batteries, reducing mechanical stress on the flange portions and allowing for die-molding of frame bodies to accommodate varying battery thicknesses, thereby enhancing productivity and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a frame body with large thickness is used to support film-covered batteries with large thickness, then the mechanical strength is improved, but the volume efficiency of the battery module is reduced
Solution Approach 1:
The frame body is designed with variable thickness rather than uniform thickness, allowing the thickness to adapt dynamically to the actual support needs at different locations. The thickness is largest where mechanical support is most needed and gradually reduces toward the center, optimizing both strength and volume efficiency.
Solution Approach 2:
Different regions of the frame body have different thicknesses tailored to their specific functional requirements. The outer peripheral portion has larger thickness for structural support and impact resistance, while the inner regions have reduced thickness to maximize battery stacking density and volume efficiency.
2Adaptability or versatility
If frame bodies of various dimensions are prepared to match different battery thicknesses, then the adaptability is improved, but the productivity is reduced
Solution Approach 1:
A single standardized frame body design with variable thickness can accommodate film-covered batteries of different thicknesses and capacities. The frame body's graduated thickness profile allows it to adapt to various battery specifications without requiring multiple customized frame sizes, thereby maintaining high productivity.
Solution Approach 2:
The frame body incorporates continuous parameter variation in its thickness profile, allowing it to adapt to different battery thicknesses through a single design. This parameter gradient enables universal compatibility across different battery specifications while maintaining consistent manufacturing processes.
3Strength
If the outer peripheral portion of the film-covered battery is supported by the whole periphery of the frame body, then the mechanical strength is improved, but the volume efficiency is reduced
Solution Approach 1:
The frame body provides concentrated support at the outer peripheral portion where mechanical strength is most needed, with the maximum thickness located at the edges. This localized thickening ensures structural integrity and impact resistance while minimizing material usage and maintaining volume efficiency in the central regions.
Data Source
AI summary
To provide a film-covered battery and a battery module having high resistance to external impact.A frame body is placed on a peripheral portion of a film-covered battery. The frame body has a protruding portion. The peripheral portion of film-covered body is supported by the protruding portion.