Battery Module Housing Structure Without Plastic Cartridges
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Solution Overview
Problem
Conventional battery modules face challenges with mechanical rigidity, heat dissipation efficiency, and increased manufacturing time and cost due to the use of plastic cartridges, which also lower energy density.
Innovation Solution
A battery module design featuring a module housing with a first and second frame, utilizing a male-female coupling unit and welding coupling for assembly, along with thermal conductive adhesives and guide protrusions to enhance mechanical stability and heat dissipation, and omitting the need for plastic cartridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic cartridges are used to protect and fix secondary batteries, then the batteries are protected and fixed in stacked form, but the mechanical rigidity is low and internal components may be easily damaged when external impact is applied
Solution Approach 1:
The patent merges the protective and fixing functions into a single module housing structure that replaces multiple plastic cartridges. The housing includes a main body and a cover that together provide both protection and positioning for the battery cells, eliminating the need for separate cartridge components for each cell.
Solution Approach 2:
The module housing is made from composite materials that provide high mechanical rigidity and impact resistance. The housing structure incorporates rigid materials that can withstand external impacts while maintaining the structural integrity needed to protect internal battery components.
2Temperature
If plastic cartridges are used to protect secondary batteries, then the batteries are fixed in stacked form, but the thermal conductivity is low and heat dissipation efficiency is seriously reduced
Solution Approach 1:
The module housing combines the structural support function with the thermal management function. The housing structure incorporates thermal conduction members that integrate with the housing to provide heat dissipation pathways, eliminating the need for separate cartridge components that would act as thermal barriers.
Solution Approach 2:
The patent changes the material parameters of the housing structure by incorporating thermal conduction members with high thermal conductivity. This modifies the thermal properties of the overall housing system to enable efficient heat dissipation while maintaining structural integrity.
3Ease of manufacture
If multiple plastic cartridges are used to protect and fix secondary batteries, then the batteries are protected, but a lot of assembly time is required and manufacturing cost increases
Solution Approach 1:
The module housing merges multiple cartridge functions into a single integrated structure that can be assembled in one piece or as fewer components. The housing includes integrated features for battery positioning, protection, and thermal management, reducing the number of assembly steps required.
Solution Approach 2:
The patent extracts the essential functions of multiple cartridges (protection, fixing, thermal management) and consolidates them into a single housing structure. This extraction of core functions eliminates unnecessary components and simplifies the assembly process.
4Quantity of substance
If multiple plastic cartridges are used to protect secondary batteries, then the batteries are fixed in stacked form, but the volume is great and energy density is lowered
Solution Approach 1:
The module housing combines the protective and structural functions into a single compact structure that occupies less volume than multiple separate cartridges. The integrated design eliminates gaps and redundant structures between multiple cartridge components, maximizing the space available for active battery materials.
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
This design simplifies the manufacturing process, enhances mechanical stability, improves heat dissipation, and increases energy density by eliminating plastic cartridges, thereby reducing assembly time and manufacturing costs.
Implementation Method 1
a welding coupling unit respectively provided to overlapped ends of the bent portions of the first frame and the second frame so that the first frame and the second frame are coupled to each other by welding
Implementation Method 2
thermal conductive adhesives
Data Source
AI summary
A battery module includes a module housing with a simplified assembling process and an improved energy density. The battery module includes a battery assembly configured to include a plurality of secondary batteries and has front, rear, upper, lower, left and right sides; and a module housing including a first frame located at the left side of the battery assembly and having a plate shape with opposing ends bent rightward so that bent portions thereof are respectively located at the upper side and the lower side of the battery assembly, and a second frame located at the right side of the battery assembly and having a plate shape with opposing ends bent leftward so that bent portions thereof are respectively located at the upper side and the lower side of the battery assembly and are coupled with the bent portions of the first frame, respectively.