Integrated Battery Module Housing for High-Power Cell Stack Support
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Solution Overview
Problem
Current battery module designs require multiple components and a complex manufacturing process to meet high power demands, leading to increased weight, cost, and inefficiency.
Innovation Solution
A battery module design featuring a plurality of cell stacks with insulation and a module housing that includes receiving parts with fixing walls, end walls, and a separation wall, which eliminates the need for a separate module frame, simplifying the structure and manufacturing process while enhancing power capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple separate components (module frame, receiving parts, fixing structures) are used to meet high power demands, then the power capacity is improved, but the device complexity and weight increase
Solution Approach 1:
The patent merges the module frame, receiving parts, and fixing structures into a single integrated module housing. The housing simultaneously serves as the structural frame, the receiving container for cell stacks, and the fixing mechanism through its configured walls and engagement features. This consolidation reduces the number of separate components while maintaining the required power capacity through optimized internal arrangement of multiple cell stacks.
2Strength
If multiple separate components are used to ensure structural stability, then the strength is improved, but the manufacturing process complexity increases
Solution Approach 1:
The module housing is designed as an integrated structure that combines frame, receiving, and fixing functions into a single manufacturable component. This reduces the number of assembly steps and manufacturing processes required compared to producing and assembling multiple separate components, while maintaining structural stability through the housing's configured walls and engagement features.
3Strength
If a separate module frame is used to hold cell stacks, then the structural support is improved, but the weight increases
Solution Approach 1:
The module housing integrates the structural support function into the housing itself rather than requiring a separate frame. The housing walls and engagement features provide the necessary structural support to hold and secure cell stacks, eliminating the need for an additional frame structure and thereby reducing overall module weight.
4Reliability
If multiple separate components and complex assembly structures are used, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The integrated module housing design reduces the number of components that need to be manufactured, assembled, and quality-checked. This consolidation simplifies the manufacturing process and reduces assembly steps, thereby lowering manufacturing costs while maintaining system reliability through the housing's configured structural and securing features.
Data Source
AI summary
A battery module includes: a plurality of cell stacks, each of the cell stacks including: a plurality of unit cells arranged in a first direction; and an insulation member around the plurality of unit cells; and a module housing, in which a plurality of receiving parts are provided, ones of the cell stacks from among the plurality of cell stacks being located in a receiving part from among the plurality of receiving parts, and each of the receiving parts includes a fixing wall, the fixing wall being around the cell stack received therein and being in contact with the cell stack, and the module housing includes end walls at respective sides of each of the receiving parts in the first direction to engage end surfaces of respective sides of the cell stack received in the respective receiving part in the first direction.