Compact Battery Module Joint Structure for Vehicle Mounting
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Solution Overview
Problem
Existing middle- or large-sized battery modules for vehicles have complex assembly processes, increased size due to protruding joint structures, and high manufacturing costs, with insufficient structural stability against impacts like vibrations.
Innovation Solution
A battery module design featuring a lower module case with dual coupling parts for upward and downward couplings and an upper module case with corresponding joint holes, allowing secure and compact coupling between the cases, using insert nuts or a step-shaped structure for enhanced stability and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plurality of members are used to mount battery cells or unit modules in a battery module case and to mechanically couple the case to a mounting member, then the mechanical coupling is achieved, but the assembly process becomes very complicated and the total size of the system is increased
Solution Approach 1:
The joint structure integrates multiple functions into a single component: the joint body simultaneously serves as a mounting member for battery cells/modules, a coupling element to attach to the vehicle body, and a structural support element. This merging eliminates the need for separate members for each function, simplifying the assembly process while maintaining mechanical coupling stability
Solution Approach 2:
The joint structure is designed as a multi-functional component that can perform multiple roles: providing mechanical coupling between the battery module case and vehicle body, serving as a mounting structure for battery cells or unit modules, and potentially providing structural support and impact absorption. This universal design reduces the total number of components needed in the system
2Reliability
If a plurality of members are used for mechanical joint, then the coupling is achieved, but the manufacturing costs are increased
Solution Approach 1:
By combining multiple functions into a single joint structure, the manufacturing cost is reduced through fewer components to produce, inventory, and assemble. The integrated design allows for potential economies of scale and reduces the cumulative manufacturing cost of multiple separate members while maintaining coupling stability
3Ease of manufacture
If the joint structure is formed only at one side of the battery frame, then the assembly is simplified, but the batteries are spaced apart from the battery frame and the joint structure is not structurally stable against impacts
Solution Approach 1:
The joint structure is provided at multiple locations on the battery module case (both upper and lower sides), creating multiple attachment points that distribute mechanical loads and improve structural stability. This segmentation approach allows the batteries to be securely mounted close to the frame while maintaining stability against impacts and vibrations from multiple directions
4Reliability
If protruding joint structures are used for coupling, then the coupling function is achieved, but the total size of the system is increased
Solution Approach 1:
The joint structure is designed to be integrated within or flush with the battery module case surface, rather than protruding outward. The coupling elements are nested within the case structure or positioned to minimize external dimensions, allowing the batteries to be mounted close to the frame without increasing the overall system volume
Data Source
AI summary
Disclosed herein is a battery module including a charge and discharge stack, constituted by a plurality of secondary battery cells that can be charged and discharged or a plurality of unit modules having the secondary battery cells, mounted between an upper module case and a lower module case, wherein the lower module case is provided with joint structures including coupling parts (upper and lower coupling parts) for allowing both upward and downward couplings, and the upper module case is provided with joint holes communicating with the upper coupling parts of the joint structures. The battery module according to the present invention has the effect of reinforcing the low mechanical strength of the battery cells while the weight and size of the battery module is minimized. Also, the battery module according to the present invention is mounted to an inner frame of a vehicle or an additional frame fixed in the vehicle by a simple joint structure without using a plurality of members for a mechanical joint, whereby the manufacturing costs of the battery module are generally decreased. Furthermore, the battery module according to the present invention is safely protected when vibrations are generated from the vehicle during the driving of the vehicle. In addition, it is possible to easily manufacture a middle- or large-sized battery system having desired power and capacity using the battery module as a unit body.