Battery Module Insulator Ribs for Safe Laser Welding
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Solution Overview
Problem
Existing battery module welding processes can damage internal components due to laser penetration and weld spatters during the welding of the module frame and end plate, posing risks to the battery cell stack and other internal components.
Innovation Solution
A battery module design featuring an insulator with ribs and protruding parts that block laser beams and weld spatters, using materials like polycarbonate, polypropylene, or polyethylene terephthalate, to protect internal components during welding by intercepting and containing the weld spatters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is performed to bond the module frame and end plate, then the bonding strength and manufacturing efficiency are improved, but internal components including battery cells may be damaged due to laser penetration and weld spatters
Solution Approach 1:
A protective cover is introduced as an intermediary component between the welding area and the battery cells. This cover blocks laser beams and weld spatters from reaching internal components, allowing laser welding to proceed efficiently without damaging the battery cells. The protective cover serves as a mediator that enables the welding process to occur safely.
Solution Approach 2:
The protective cover is positioned in advance before welding begins, creating a preliminary barrier that prevents harmful laser penetration and spatter from affecting internal components. This preliminary protective action ensures that when welding occurs, the battery cells are already shielded from potential damage.
2Ease of manufacture
If the module frame and end plate are welded directly without protection, then the manufacturing process is simple and fast, but the reliability of internal components is compromised due to laser and spatter damage
Solution Approach 1:
The protective cover acts as a simple intermediary component that can be easily integrated into the existing manufacturing process. It provides reliable protection for internal components while maintaining manufacturing simplicity, as the cover can be installed before welding and removed after bonding is complete.
Solution Approach 2:
The protective cover is designed as a separate, removable component rather than a permanent part of the module structure. This segmentation allows it to be easily installed and removed during manufacturing, maintaining ease of production while providing necessary protection for component reliability.
3Object-affected harmful factors
If protective measures are added during welding, then the safety of internal components is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The protective cover is a straightforward intermediary component with a simple structure designed specifically for protection. Rather than complicating the overall module design, it adds a single, focused protective element that can be easily manufactured and integrated, minimizing the increase in device complexity.
Solution Approach 2:
The protective cover provides localized protection only in the specific area where laser welding occurs and where battery cells are vulnerable. This targeted approach protects internal components from harm without requiring complex protective structures throughout the entire device, thereby limiting the increase in overall structural complexity.
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 effectively prevents damage to internal components by blocking laser beams and weld spatters, ensuring the integrity and safety of the battery module during the welding process.
Implementation Method 1
an insulator with ribs and protruding parts that block laser beams and weld spatters
Implementation Method 2
an insulator with ribs and protruding parts that block laser beams and weld spatters, to protect internal components during welding by intercepting and containing the weld spatters
Data Source
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AI summary
The battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked; a module frame that houses the battery cell stack and has an opened front surface and an opened rear surface facing each other; an end plate that covers each of the front surface and the rear surface of the module frame; and an insulator interposed between the battery cell stack and the end plate, wherein the module frame includes a first joining surface formed on sides constituting each of the front surface and the rear surface, wherein the end plate includes a second joining surface joined to the first joining surface, and wherein the insulator includes a rib extending in a direction in which the battery cell stack is located.