Battery Module Frame Design for Swelling Control
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Solution Overview
Problem
Existing battery modules face challenges in preventing battery cell swelling, which requires increased frame thickness, leading to inefficient space utilization and potential damage during assembly.
Innovation Solution
A battery module design featuring a U-shaped module frame with open sides, a busbar frame, insulating plate, and end plates with hooking and stepped portions to accommodate and control the battery cell stack, allowing for effective swelling management without increasing frame thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the frame member is increased to control swelling of the battery cell, then the swelling control is improved, but the space utilization is deteriorated
Solution Approach 1:
The frame structure is segmented into multiple functional components: a U-shaped module frame for basic support, an upper plate for compression force application, and end plates with stepped portions for swelling control. This segmentation allows each component to perform its specific function efficiently without requiring the entire frame to be thick, thereby improving space utilization while maintaining swelling control capability.
Solution Approach 2:
The invention transitions from controlling swelling through increased frame thickness (one-dimensional solution) to using a multi-dimensional approach with stepped portions extending in the stacking direction and an upper plate applying compression force. This dimensional change allows effective swelling control without increasing the horizontal frame thickness, thus preserving space utilization.
2Ease of operation
If sufficient clearance is secured between the battery cell stack and the mono frame for stable assembly, then the assembly stability is improved, but the wasted space increases
Solution Approach 1:
The upper plate acts as an intermediary component between the battery cell stack and the frame structure. It provides the necessary clearance for stable assembly while applying compression force to prevent swelling, eliminating the need for excessive clearance in the horizontal direction and thus reducing wasted space.
Solution Approach 2:
The invention changes the clearance parameter from horizontal clearance (in the inserting direction) to vertical clearance in the stacking direction, where the stepped portions and upper plate provide the necessary space for assembly stability without increasing the overall horizontal dimensions of the frame.
Data Source
AI summary
A battery module according to an embodiment of the present disclosure includes: a battery cell stack having a plurality of battery cells stacked in a stacking direction, a module frame accommodating the battery cell stack and having an opened upper portion; an upper plate covering the battery cell stack on the upper portion of the module frame, a busbar frame connected to the battery cell stack, and an end plate located on both sides of the battery cell stack, wherein the module frame has a structure for opening the battery cell stack along the stacking direction, and wherein the end plate covers a stacked surface of the battery cell stack on open both sides of the module frame.