Battery Module Central Wall Structure for Heat Isolation and Assembly
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Solution Overview
Problem
The conventional process of manufacturing battery modules is complex due to the individual manufacturing and assembly of sub-modules with different structures, which complicates the overall process and lacks efficient heat management between sub-modules.
Innovation Solution
A battery module design featuring identical sub-modules with a central wall of rotationally symmetrical central walls that couples with side covers and upper/lower covers to prevent heat propagation and enhance mechanical rigidity, using fastening grooves and guide grooves for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sub-modules are manufactured individually with different structures, then each sub-module can be customized for specific functions, but the overall manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The battery module is divided into multiple identical sub-modules, each with the same standardized structure. This segmentation allows for mass production of uniform units that can be assembled in different configurations to meet various application requirements, thus maintaining adaptability while simplifying the manufacturing process.
Solution Approach 2:
A universal sub-module design is implemented where each sub-module has identical standardized components including the same housing structure, battery cells, and connection terminals. This universal design enables the same sub-module to be used in various positions and configurations within the battery module, providing versatility without requiring custom manufacturing for each unit.
2Length of moving object
If sub-modules are assembled and welded together side by side, then a long battery module can be formed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
Sub-modules are pre-assembled with all necessary components (battery cells, housing, connection terminals) already in place before final assembly. This preliminary preparation allows for faster final assembly operations and reduces the overall manufacturing time while maintaining the ability to create long battery modules by simply adding more pre-assembled units.
Solution Approach 2:
Multiple sub-modules are combined side by side in a standardized assembly process. The identical structures of the sub-modules allow for efficient parallel assembly operations and simplified connection processes, thereby improving productivity while achieving the desired battery module length.
3Strength
If a central wall is coupled to side covers and upper/lower covers, then mechanical rigidity is improved, but the device structure becomes more complex
Solution Approach 1:
The central wall is designed with an asymmetric structure that optimizes mechanical support while minimizing material usage. The wall features varying thickness and reinforcement zones strategically positioned to provide maximum rigidity where needed, reducing overall structural complexity compared to a uniformly thick design.
Solution Approach 2:
The central wall incorporates curved surfaces and rounded transitions instead of sharp angles, which distribute stress more effectively and enhance mechanical rigidity. The curved geometry also simplifies manufacturing processes and reduces the number of separate components needed, thereby lowering structural complexity.
4Manufacturing precision
If identical sub-modules with rotationally symmetrical central walls are used, then manufacturing process is simplified and consistency is improved, but heat management between sub-modules becomes more challenging
Solution Approach 1:
A central wall with rotationally symmetrical design is positioned between adjacent sub-modules to serve as a thermal barrier. The symmetric geometry ensures uniform heat distribution and prevents localized hot spots, while the wall itself acts as an intermediary structure that manages heat flow between identical sub-modules, maintaining manufacturing precision without compromising thermal management.
Solution Approach 2:
The central wall features locally optimized thermal properties with varying material composition or thickness in different zones. Specific regions of the wall are designed with enhanced thermal insulation properties to block heat propagation between sub-modules, while other regions maintain structural integrity, thus achieving both manufacturing consistency and effective heat management.
Data Source
AI summary
An eco-friendly power source such as a battery module is provided for a transportation vehicle, including: a first sub-module and a second sub-module respectively including a cell stack in which a plurality of battery cells are stacked; and a central wall disposed between the first sub-module and the second sub-module, wherein the central wall includes a first central wall facing the first sub-module and a second central wall facing the second sub-module, wherein the first central wall has a rotationary symmetrical shape of the second central wall around a first axis.