Battery Module Housing Segmentation for Assembly
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Solution Overview
Problem
Conventional battery modules with I-shaped frames face challenges in assembling cell stacks due to complexity, potential deformation of the housing, damage to the cell stack, and increased welding defects, which limit the number of battery cells and height of the cell stack, as well as inefficient cooling and heat propagation management.
Innovation Solution
A battery module design featuring a housing with a partitioned accommodation space formed by a first and second frame, coupled in a fitting manner, allowing for easy insertion and improved assembly of cell stacks, with a busbar assembly that reduces assembly complexity and enhances cooling through thermally conductive materials and heat insulating members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the module housing is widened to insert the cell stack, then the cell stack can be accommodated, but the module housing may deform and the assembly process becomes complicated
Solution Approach 1:
The module housing is divided into a first housing and a second housing that can be assembled separately. The cell stack is inserted into the first housing, and then the second housing is coupled to form the complete module housing. This segmentation eliminates the need to widen a single large opening, simplifying the assembly process and reducing the risk of housing deformation.
2Volume of moving object
If the module housing is widened to insert the cell stack, then the cell stack can be accommodated, but damage may occur to the cell stack due to contact with the module housing
Solution Approach 1:
By dividing the housing into two separate parts that are assembled around the cell stack rather than requiring a single large opening, the cell stack is protected from damage during insertion. The segmented approach allows for more controlled assembly and reduces direct contact stresses on the cell stack.
3Adaptability or versatility
If multiple cell stacks are connected to a single busbar assembly, then the electrical connection is achieved, but assembly tolerance occurs and welding defects increase
Solution Approach 1:
The busbar assembly is divided into a first busbar assembly and a second busbar assembly, with each connected to its corresponding cell stack. This segmentation eliminates the cumulative tolerance issues that would arise from connecting multiple cell stacks to a single busbar assembly, thereby improving manufacturing precision and reducing welding defects.
4Productivity
If the number of battery cells in the cell stack is increased to improve assembly performance, then assembly efficiency improves, but the height of the cell stack cannot be increased
Solution Approach 1:
The housing structure incorporates a recessed portion that provides additional vertical space, allowing the cell stack height to be increased without proportionally increasing the overall module height. This dimensional adjustment enables more battery cells to be stacked while maintaining assembly efficiency.
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 design simplifies the assembly process, reduces deformation and damage risks, increases the number of battery cells and module height, and improves cooling efficiency, while effectively managing heat propagation between cells and stacks.
Implementation Method 1
a heat insulating member blocking heat transfer between the adjacent cell stacks
Implementation Method 2
improves cooling efficiency, while effectively managing heat propagation between cells and stacks
Data Source
AI summary
A battery module includes a cell stack in which a plurality of battery cells are stacked; and a housing having a plurality of accommodation spaces partitioned by a partition member, to accommodate a plurality of the cell stack, wherein the housing includes a first frame and a second frame, coupled to each other to form the plurality of accommodation spaces, wherein the first frame and the second frame include a coupling portion that is coupled in a fitting coupling manner, respectively.