Battery Module Frame Structure for Resin Gap and Insulation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in assembly efficiency and insulation performance due to large clearances and unnecessary space utilization, particularly in middle or large-sized modules, which affect thermal conductivity and structural integrity.
Innovation Solution
A battery module design featuring a modified frame structure with a bus bar frame, pad and film parts, and a thermal conductive resin layer, which reduces gaps and enhances insulation through an integrated overflow prevention mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mono frame with opened front and rear surfaces is used to house the battery cell stack, then the assembly process requires large clearance for horizontal insertion, but this leads to excessive use of thermal conductive resin and increased frame height
Solution Approach 1:
The invention divides the frame into a cell block that houses the battery cell stack and a separate insulating member that provides clearance control. This segmentation allows the cell block to be assembled with minimal clearance while the insulating member manages the thermal conductive resin application, resolving the contradiction between ease of assembly and resin usage.
Solution Approach 2:
The insulating member acts as an intermediary element between the battery cell stack and the frame. It provides the necessary clearance control and manages thermal conductive resin application, allowing the main frame structure to be compact while still enabling proper assembly and thermal management.
2Ease of operation
If the mono frame height is increased to accommodate assembly tolerance, then stable horizontal assembly is achieved, but unnecessary wasted space is generated
Solution Approach 1:
The insulating member provides localized clearance and tolerance accommodation only where needed at the interface between the battery cell stack and frame, rather than increasing the overall frame height. This allows assembly stability to be achieved locally without adding unnecessary volume to the entire frame structure.
3Temperature
If a thermal conductive resin layer is formed between the battery cell stack and mono frame, then heat transfer and fixing are achieved, but large clearance increases resin consumption
Solution Approach 1:
The insulating member serves as an intermediary that precisely positions the thermal conductive resin layer, ensuring it is applied only where necessary for heat transfer and fixing. This intermediary structure prevents excessive resin application while maintaining effective thermal conduction between the battery cell stack and frame.
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 new design improves assembly efficiency, reduces unnecessary space, and strengthens insulation performance while maintaining thermal conductivity, thereby optimizing space utilization and structural stability.
Implementation Method 1
A thermal conductive resin layer (not shown) may be formed between the battery cell stack 12 and the mono frame 20. The thermal conductive resin layer can play a role of transferring the heat generated from the battery cell stack to the outside of the battery module
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked, a bus bar frame coupled to each of the front and rear ends of the battery cell stack, a frame member that houses a cell block including the battery cell stack and the bus bar frame, a pad part located at one end of the bottom part of the frame member, and a film part connected to the pad part and protruding toward the bus bar frame.