Battery Module With Metal Sheathing And Caps
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Solution Overview
Problem
Existing battery modules face challenges in minimizing size and weight while enhancing mechanical strength, simplifying detection means installation, and preventing short circuits during assembly and operation, particularly in medium- or large-sized modules used for vehicles.
Innovation Solution
A battery module design featuring two pouch-shaped battery cells with electrode terminals at both ends, mounted on a frame member with a metal sheathing member and caps, incorporating a 'U'-shaped frame for easy detection terminal connection and reduced exposure of connecting wires, and using a high-strength lightweight metal sheathing member to enhance mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a pouch-shaped battery with aluminum laminate sheathing is used, then weight is reduced and manufacturing cost is lowered, but mechanical strength is insufficient
Solution Approach 1:
The patent uses a composite sheathing structure combining aluminum laminate material with resin layers. The aluminum laminate provides lightweight properties while the resin layers enhance mechanical strength and sealability. This composite approach resolves the contradiction by integrating materials with complementary properties - the aluminum layer reduces weight while the resin layers provide structural reinforcement.
2Strength
If battery cells are mounted in a pack case to increase mechanical strength, then structural stability is improved, but size and weight increase
Solution Approach 1:
The patent merges the protective case function with the battery cell structure itself by using the reinforced pouch-shaped battery as the structural element. The aluminum laminate sheathing with resin layers serves both as the battery enclosure and as the structural protective element, eliminating the need for a separate heavy pack case while maintaining structural stability.
3Reliability
If detection means are added to monitor battery operation, then safety and operational efficiency are improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent integrates detection terminals directly into the existing electrode terminal structure. The same terminal that serves electrical connection purposes also functions as the detection point for monitoring battery operation. This multi-functionality approach allows safety monitoring without adding separate detection components, thereby maintaining simplicity in both design and assembly.
4Ease of operation
If electrode leads protrude from the sheathing member, then electrical connection is enabled, but short circuit risk increases during assembly and operation
Solution Approach 1:
The patent introduces resin layers as an intermediary material between the electrode leads and the external environment. These resin layers provide electrical insulation while allowing the electrode leads to protrude for connection. The intermediary resin layer prevents direct contact between exposed electrode leads and other conductive elements, thereby eliminating short circuit risk while maintaining electrical connectivity.
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
This design minimizes weight and size while increasing mechanical strength, simplifies detection means installation, and prevents short circuits, enabling efficient assembly and operation of battery modules with improved electrical connections for medium- or large-sized applications.
Implementation Method 1
it is possible to bond the opposite sides 14a and upper and lower ends 14b and 14c of the upper and lower sheathing parts of the sheathing member 14, which are in contact with each other, to each other by applying heat and pressure to the opposite sides 14a and upper and lower ends 14b and 14c of the upper and lower sheathing parts of the sheathing member 14 so as to weld the resin layers to each other
Data Source
Figure 1
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AI summary
Disclosed herein is a battery module including two battery cells, each of which has electrode terminals formed at upper and lower ends thereof. The battery module further includes a frame member, to which upper-end sealing parts, lower-end sealing parts, and one-side sealing parts of the battery cells are mounted, a metal sheathing member for covering the outer surfaces of the battery cells while the battery cells are mounted to the frame member, and caps (an upper-end cap and a lower-end cap) mounted to the upper and lower ends of the battery cells, respectively, which are covered by the metal sheathing member.