Battery Module Overlap Sidewall Structure Without Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules require a large number of parts and welding processes, leading to increased manufacturing costs and quality control burdens, as well as potential welding failures, and they do not effectively address the structural rigidity and space efficiency needed for high-performance applications.
Innovation Solution
A battery module design featuring a non-welding mechanical fastening structure with a double sidewall configuration that overlaps in the stacking direction, reducing the number of parts and eliminating the need for welding, while enhancing structural rigidity and internal space efficiency through cross-fastening and the use of a gasket for improved waterproof and dustproof performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional six-side exterior case with multiple parts is used, then the battery module can be assembled, but the number of parts and welding processes increases, leading to higher manufacturing costs and quality control burdens
Solution Approach 1:
The patent merges multiple case parts into a single integrated case structure that surrounds the battery cells. Instead of using separate front, rear, left, and right case pieces that require welding, the invention employs one piece case that eliminates the need for welding processes while reducing the total number of parts, thereby lowering manufacturing costs and simplifying assembly.
Solution Approach 2:
The case is designed with a removable cover portion that separates the battery module into accessible sections. This segmentation allows for easy maintenance and battery replacement while maintaining the overall integrated structure, combining the benefits of both single-piece simplicity and modular accessibility.
2Reliability
If welding processes are used to couple exterior case parts, then the case can be assembled, but quality control burden increases and welding failures may occur
Solution Approach 1:
The patent replaces the welding process with a mechanical fastening system using fastening members such as bolts or rivets. This substitution eliminates the quality control issues associated with welding while maintaining structural integrity. The mechanical fastening method is more reliable and easier to quality-check, as it does not involve complex thermal processes that can lead to defects.
3Ease of manufacture
If multiple case parts are coupled together, then the battery module can be formed, but manufacturing costs increase due to multiple coupling processes
Solution Approach 1:
By integrating multiple case components into a single one-piece structure, the patent eliminates the need for multiple coupling operations. This merging reduces both the number of parts to be managed and the number of assembly steps required, thereby improving productivity while reducing manufacturing costs associated with multiple coupling processes.
4Strength
If a conventional exterior case design is used, then the battery cells can be housed, but structural rigidity is insufficient to effectively suppress battery cell expansion
Solution Approach 1:
The patent introduces a double sidewall structure that overlaps in the stacking direction of battery cells. This dimensional enhancement adds rigidity to the case by creating overlapping vertical walls that provide better support and constraint for the battery cells, effectively suppressing expansion while maintaining a relatively simple overall case design.
Solution Approach 2:
The case incorporates a removable cover portion that can be dynamically opened and closed. This dynamic feature allows for easy access to battery cells for maintenance or replacement while the closed state provides full structural support. The design adapts between accessible and constrained states to serve different operational needs.
Data Source
AI summary
The present invention provides a battery module which includes: a battery stack formed by stacking a plurality of battery cells on each other, each of which includes electrode tabs; a first case unit including a bottom section which surrounds one side of the battery stack and a pair of first sidewalls located on both sides of the battery stack in a direction in which battery cells are stacked; and a second case unit including a top section which surrounds the other side of the battery stack and a pair of second sidewalls located on both sides of the battery stack in the direction in which battery cells are stacked, wherein the first sidewall and the second sidewall are located on both sides of the battery stack in the direction in which battery cells are stacked, in a state in which at least portions thereof are overlapped with each other.