Battery Module Frame Assembly With Two-Piece Integrated Housing
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Solution Overview
Problem
The existing battery module frame assembly process is complex and inefficient, requiring multiple frames and welding jigs, leading to increased time, cost, and potential defects due to cumulative tolerances and unnecessary space usage.
Innovation Solution
A battery module design featuring a first frame covering the lower and side surfaces and a second frame with an integrally formed upper and side surfaces, simplifying the assembly process by reducing the number of outer frame parts to two, which are coupled using welding and a press method for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a monoframe structure with open front and rear surfaces is used to accommodate the cell stack, then the assembly process is simplified, but the frame height must be designed high to accommodate the maximum height of the cell stack and assembly tolerance, resulting in wasted space
Solution Approach 1:
The frame is divided into two separate frames: a lower frame that covers the lower side surface and both side surfaces of the cell stack, and an upper frame that covers the upper side surface and front and rear surfaces. This segmentation allows each frame to be optimized independently, eliminating the need for excessive height in a single monoframe structure.
Solution Approach 2:
The patent transitions from a single-frame design to a two-frame design, effectively adding a dimensional division in the vertical direction. This allows the lower frame to provide structural support at the bottom while the upper frame covers the top and ends, optimizing space utilization without requiring excessive height in any single frame component.
2Reliability
If three or more frames including monoframe and end plates are welded together, then the battery module structure is protected, but the welding process becomes complex requiring welding jig management and tighter dimension control, increasing time and cost
Solution Approach 1:
The protective frame structure is segmented into two main frames (lower and upper) rather than three or more separate components. This reduces the number of welding joints required, simplifying the welding process and eliminating the need for complex welding jig management while maintaining adequate structural protection.
Solution Approach 2:
The functions of multiple frames (monoframe and end plates) are merged into two integrated frames. The upper frame combines the functions of what would traditionally be separate end plates and upper frame components, reducing the total number of parts and welding operations needed while preserving the protective function.
3Reliability
If three or more frames are welded together, then the battery module structure is complete, but cumulative tolerances between frames may prevent satisfaction of gap conditions required at welding time
Solution Approach 1:
By segmenting the frame into only two components (lower and upper frames) rather than three or more, the number of cumulative tolerance accumulations is reduced. This minimizes the propagation of dimensional variations and makes it easier to satisfy welding gap conditions without requiring excessively tight dimension control on each individual component.
Data Source
AI summary
Discussed are a battery module and a method of manufacturing the battery module. The battery module includes a battery cell stack in which a plurality of battery cells are stacked; a first frame having a bottom surface and opposite side surfaces respectively covering a lower side surface and opposite side surfaces of the battery cell stack; and a second frame having an upper surface and front and rear surfaces respectively covering an upper side surface and front and rear surfaces of the battery cell stack, wherein the upper surface of the second frame and the front and rear surfaces of the second frame are integrally formed.