Integrated Battery Module Frame for Better Weldability
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Solution Overview
Problem
The existing battery module structures face issues with weldability due to the use of dissimilar materials in the end plate and U-shaped frame, leading to defects during welding.
Innovation Solution
A battery module design featuring a bowl-shaped module frame with integrated front, rear, left, and right plates, where the module mounting part is formed in a recessed area, allowing for improved weldability and simplified manufacturing by eliminating the need for separate casting of the end plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end plate is separately manufactured by casting method and welded to the U-shaped frame, then the module mounting parts can be formed on the end plate, but defects between dissimilar metals occur during welding
Solution Approach 1:
The end plate and U-shaped frame are merged into a single integrally formed module frame, eliminating the welding interface between dissimilar metals. The module frame is formed as a unified structure with the bowl-shaped bottom surface and upward extending side surfaces, removing the separate end plate component and its associated welding defects.
Solution Approach 2:
The problematic welding step between dissimilar metals is extracted and removed from the manufacturing process. By eliminating the separate end plate and its welding to the U-shaped frame, the source of welding defects is completely removed while module mounting parts are still provided through the integrally formed structure.
2Ease of manufacture
If the end plate is separately manufactured and welded to the U-shaped frame, then the battery cell stack can be housed, but the module structure becomes complex
Solution Approach 1:
The end plate and U-shaped frame are combined into a single integrally formed module frame, reducing the number of components from two separate parts to one unified structure. This simplification maintains the housing capability for the battery cell stack while eliminating the complexity of separate manufacturing and assembly steps.
3Ease of manufacture
If dissimilar materials are used for the U-shaped frame and end plate, then the end plate can be cast with module mounting parts, but weldability deteriorates
Solution Approach 1:
The module frame is constructed from a single material composition throughout, eliminating the dissimilar metal interface. The integrally formed structure uses homogeneous material properties, allowing uniform manufacturing processes and eliminating welding between different metal types, thereby improving weldability while maintaining manufacturing capability.
Data Source
AI summary
A battery module according to embodiments of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked, a module frame that is formed into a bowl type of a bottom surface and front, rear, left and right surfaces and houses the battery cell stack; and an upper plate that covers the upper side of the battery cell stack and is coupled to the module frame, wherein the module frame comprises a bottom part, front and rear plates, and left and right plates, wherein the bottom part, the front and rear plates, and the left and right plates are integrally formed, and wherein a recessed part is formed at a portion where a bottom edge connected to the front and rear plates meet with a bottom edge connected to the left and right plates.