Battery Module Housing With Insert-Molded Reinforcement
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Solution Overview
Problem
The assembly productivity and cost of battery modules are hindered by the use of welding and fasteners in constructing module housings, which can increase complexity and expense.
Innovation Solution
A battery module with a module housing made of synthetic resin, incorporating a reinforcing member of greater strength, such as metal, and a busbar holder portion, which is integrally formed without welding, along with features like insert molding and a cooling plate for improved structural integrity and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or fasteners are used to couple the pair of side plates to the pair of end plates in the module housing, then the structural strength and rigidity of the housing are improved, but the assembly productivity decreases and manufacturing costs increase
Solution Approach 1:
The patent combines multiple housing components (side plates and end plates) into a single integrally formed module housing made of synthetic resin. This merging eliminates the need for welding or fasteners to couple separate plates, thereby resolving the contradiction by maintaining structural integrity while significantly improving assembly productivity and reducing manufacturing costs.
Solution Approach 2:
The patent employs composite material strategy by using synthetic resin for the main housing body and incorporating metal reinforcing members in specific areas where high strength is required. This allows the housing to achieve adequate structural strength without relying on welded or fastened metal plate constructions, thus improving assembly productivity while maintaining necessary strength.
2Stability of the object's composition
If welding or fasteners are used to construct the module housing, then the structural integrity is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent merges multiple housing components into a single integrally formed synthetic resin housing, eliminating the complexity of welding or fastening operations. The structural integrity is maintained through the integral design and strategic placement of reinforcing members, thereby reducing manufacturing complexity while preserving structural stability.
Solution Approach 2:
The patent applies local quality by incorporating metal reinforcing members only in specific areas where high strength and rigidity are required, rather than constructing the entire housing from metal plates. This localized reinforcement maintains structural integrity in critical areas while simplifying the overall manufacturing process compared to full metal construction with welding or fasteners.
3Strength
If metal reinforcing members are incorporated into the synthetic resin housing, then the strength and rigidity of the housing are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning metal reinforcing members into molds before injecting the synthetic resin material. The reinforcing members are strategically placed in areas requiring enhanced strength, and the resin is then molded around them in a single integrated process. This preliminary positioning ensures proper placement while maintaining manufacturing efficiency, as the reinforcing members are incorporated during the molding process itself rather than requiring separate assembly steps.
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
Enhances assembly efficiency, reduces costs, and improves thermal management and safety through the use of a robust, integrally formed housing with enhanced thermal conductivity and fire prevention mechanisms.
Implementation Method 1
The reinforcing member may be inserted in a mold for molding the module housing and joined to the sidewall portion by insert molding
Implementation Method 2
a module housing made of a synthetic resin material... improves thermal management and safety through the use of a robust, integrally formed housing with enhanced thermal conductivity
Implementation Method 3
a potting material that closes a gas through hole aligned with the cell vent and is configured to be melted or ruptured by a gas to open the gas through hole
Data Source
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AI summary
A battery module includes a battery cell stack including a plurality of battery cells, a plurality of busbars electrically connecting the plurality of battery cells, and a module housing made of a synthetic resin material, and including a busbar holder portion supporting the plurality of busbars, and a sidewall portion surrounding side surfaces of the battery cell stack that does not face the busbar holder portion and connected to the busbar holder portion.