Battery Module Split Lower Case with Engaging Groove
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Solution Overview
Problem
Existing battery modules face issues with spatter generation during welding of metal lower cases, weight, and ineffective electrical insulation, leading to functional failures and instability in connections with heat conducting plates.
Innovation Solution
A battery module design featuring a lower case with an engaging groove and a heat conducting plate with an inserted portion, forming a split structure and using insulating materials to prevent spattering, with a hot rivet connection for stability, and a structural adhesive for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal lower case is used for structural strength, then strength is improved, but spatter is generated during welding causing functional failures
Solution Approach 1:
The lower case is divided into multiple modular components (side plates, end plates, bent plates) that are injection molded separately and then assembled. This segmentation eliminates welding operations, thereby preventing spatter generation while maintaining structural integrity through mechanical connection and adhesive bonding.
Solution Approach 2:
The traditional welding process is replaced with injection molding and adhesive bonding. The lower case components are formed through injection molding and connected via mechanical fitting (engaging grooves and inserted portions) combined with structural adhesive, substituting the welding mechanical system with a composite joining system that eliminates spatter.
2Strength
If a metal lower case is used for structural strength, then strength is improved, but weight increases significantly
Solution Approach 1:
The lower case transitions from solid metal construction to a composite structure combining plastic materials (injection molded components) with metal reinforcement elements (heat conducting plate with inserted portions). This composite approach reduces overall weight while maintaining structural strength through the synergistic combination of material properties.
3Strength
If a metal lower case is used, then structural strength is improved, but electrical insulation becomes problematic requiring additional parts
Solution Approach 1:
The metal lower case is replaced with injection molded plastic components that inherently provide electrical insulation. The engaging grooves and inserted portions create mechanical connections that simultaneously provide both structural strength and electrical insulation, eliminating the need for separate insulation parts and reducing device complexity.
4Strength
If welding is used to connect the lower case to the heat conducting plate, then connection strength is improved, but spatter generation occurs
Solution Approach 1:
An intermediary connection system is introduced between the lower case and heat conducting plate, consisting of engaging grooves, inserted portions, and structural adhesive. This intermediary mechanism transfers the connection function from direct welding to a multi-component joining system that achieves connection strength without spatter generation.
5Reliability
If a split structure with engaging groove and inserted portion is used, then connection stability is improved, but device complexity increases
Solution Approach 1:
The engaging groove and inserted portion features are integrated directly into the injection molded lower case components, merging the connection mechanism with the structural components themselves. This integration achieves connection stability while minimizing additional complexity, as the features are formed during the molding process rather than requiring separate parts.
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 design achieves a stable connection between the lower case and heat conducting plate, reduces weight, improves insulation, and enhances heat dissipation, thereby ensuring structural stability and quality of the battery module.
Implementation Method 1
a heat conducting plate (15)
Implementation Method 2
the lower case is provided therein with a heat conducting structural adhesive fixed at a bottom of the lower case
Data Source
AI summary
The present disclosure relates to the technical field of energy storage devices, and particularly, to a battery module. The battery module includes a lower case, a plurality of battery cells sequentially stacked and received in the lower case, and a heat conducting plate. The lower case is provided with an engaging groove, the heat conducting plate is provided with an inserted portion, and the inserted portion is inserted and fitted in the engaging groove. In the battery module according to the present disclosure, through a fitting insertion of the inserted portion in the engaging groove, a stable connection structure can be formed between the heat conducting plate and the lower case, thereby ensuring the structural stability of the battery module.