Battery Module Thermal Deformation Prevention
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Solution Overview
Problem
Lithium secondary battery modules face thermal deformation issues due to heat generated during welding, which can damage plastic components and increase replacement costs.
Innovation Solution
A battery module design where plastic components are spaced apart from welded parts at predetermined intervals, using a substrate protecting body with an interval retaining unit and separate casings combined via laser welding to prevent thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed to protect internal components from vibration or shock, then the reliability of the battery module is improved, but thermal deformation of plastic components occurs due to heat generated during welding
Solution Approach 1:
A substrate protecting body is introduced as an intermediary component between the plastic substrate and the welding area. This protecting body shields the plastic components from direct exposure to welding heat, allowing welding to proceed while preventing thermal deformation of the plastic substrate.
Solution Approach 2:
The substrate protecting body is installed on the substrate before the welding process begins. This preliminary protective measure ensures that when welding subsequently occurs, the plastic components are already protected and cannot be thermally deformed by the heat generated during the welding operation.
2Device complexity
If plastic components are placed close to welded parts for compact design, then the device complexity is reduced, but thermal deformation occurs during welding
Solution Approach 1:
The substrate protecting body serves as a mediator that enables close placement of plastic components near welded parts without risk of thermal deformation. The protecting body absorbs or blocks the heat, allowing compact design while maintaining protection of plastic components.
3Ease of manufacture
If welding is performed without protective measures, then the manufacturing process is simplified, but thermal deformation damages plastic components requiring replacement
Solution Approach 1:
The substrate protecting body is installed before welding as a preliminary protective measure. This allows the welding process itself to remain simple and straightforward, while the pre-installed protecting body prevents thermal deformation that would otherwise require costly repairs or replacements.
Solution Approach 2:
The substrate protecting body acts as a cushioning element positioned beforehand to absorb or block thermal energy. This prior cushioning prevents the harmful effects of welding heat from reaching the plastic components, eliminating the need for subsequent repairs or replacements.
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
Prevents thermal deformation of plastic components during welding, reducing replacement costs and ensuring the integrity of the battery module.
Implementation Method 1
the substrate protecting body includes an interval retaining unit so that a main body of the substrate protecting body is separated from the casing at a predetermined interval
Implementation Method 2
the first casing and the second casing is combined to each other by a laser welding
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided is a battery module. The battery module according to an embodiment of the present disclosure may include: a cartridge assembly including a plurality of cartridges receiving battery cells; a substrate protecting body combined to the cartridge assembly; a casing receiving the cartridge assembly and the substrate protecting body and surrounding the cartridge assembly and the substrate protecting body; and a cover combined to the casing, wherein the substrate protecting body includes a interval retaining unit so that a main body of the substrate protecting body is separated from the casing at a predetermined interval.