Sharable Battery Module Frames for Precise Stacking and Cooling
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Solution Overview
Problem
Battery modules with a stacking structure face increased manufacturing costs and assembly defects due to complex components and alignment issues during assembly.
Innovation Solution
A battery module design featuring sharable, identical module frames and a heatsink with coupling guides, allowing for efficient assembly and improved cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a stacking structure with multiple components is used to increase output and capacity, then the energy density and power are improved, but the manufacturing cost increases and assembly defects occur due to positioning and alignment issues
Solution Approach 1:
The patent merges the frame structure and cooling plate into a single integrated module frame that serves both structural support and thermal management functions. This integration eliminates the need for separate positioning components and reduces the number of parts requiring alignment, thereby reducing manufacturing cost and assembly defects while maintaining the stacking structure's power output capabilities
Solution Approach 2:
The module frame is designed to perform multiple functions simultaneously: providing structural support, enabling thermal management through integrated cooling plates, and facilitating precise positioning through built-in guide structures. This multi-functionality reduces the overall component count and simplifies the stacking structure while maintaining high power output
2Quantity of substance
If various components are used in the stacking structure to increase capacity, then the charge/discharge capacity is improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple functional components (frame, cooling plates, positioning structures) into a single integrated module frame. This reduction in component count directly lowers manufacturing costs while still accommodating high-capacity battery cells through the standardized stacking interface
Solution Approach 2:
The patent employs standardized, repeatable module frames that can be mass-produced and assembled through simple stacking. This standardization enables economies of scale in manufacturing while maintaining the capacity expansion achieved through multiple battery cells
3Power
If a stacking structure with multiple components is used to configure battery modules, then the output voltage and capacity are improved, but assembly defects occur due to positioning and alignment issues
Solution Approach 1:
The module frame includes self-aligning features such as guide rails and positioning protrusions that automatically ensure precise alignment during assembly. This self-service positioning mechanism eliminates the need for complex external alignment tools or procedures, thereby maintaining high output voltage through precise component positioning while simplifying the assembly process
Solution Approach 2:
The patent employs asymmetric positioning features in the module frame design, such as uniquely shaped guide structures and positioning elements that prevent misalignment. This asymmetric design ensures that components can only be assembled in the correct orientation, thereby maintaining manufacturing precision for high output voltage while reducing assembly complexity
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 reduces manufacturing costs and assembly defects while maintaining high energy density and cooling efficiency.
Implementation Method 1
a heatsink provided between the plurality of module frames and configured to allow the plurality of battery cells to be attached to both surfaces thereof
Implementation Method 2
both surfaces of the heatsink may be provided as cooling surfaces
Data Source
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AI summary
Disclosed is a battery module with improved manufacture efficiency, and a battery pack and a vehicle including the same. The battery module includes a plurality of battery cells, and a plurality of module frames configured to accommodate the plurality of battery cells, respectively, and provided as sharable frames to be coupled to each other.