Battery Module Vacuum Adsorption Region Design
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Solution Overview
Problem
Battery modules for electric vehicles are heavy and difficult to transport reliably due to their weight, as existing solutions like vacuum pads risk damaging the cover or disconnecting it during lifting, and the limited vacuum adsorption area makes secure transportation challenging.
Innovation Solution
A battery module design featuring a flat vacuum pad adsorption region on the upper surface without ribs or holes, with a three-piece housing structure (first case, second case, and cover) connected differently than the gravity direction, enhancing rigidity and strength through insulating walls and adhesive fixation, allowing for stable vacuum pad adsorption and lifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a vacuum pad is used to lift the battery module, then lifting efficiency is improved, but the cover may be damaged or disconnected due to the weight of the battery module
Solution Approach 1:
The housing is divided into a cover and a case, with the vacuum pad adsorption region specifically located on the case (bottom surface or side surface) rather than on the cover. This segmentation allows the lifting force to be applied to the stronger case structure, preventing cover damage while maintaining lifting efficiency.
Solution Approach 2:
The case is designed with enhanced local quality by providing a flat adsorption region with increased rigidity and strength compared to other parts of the housing. This localized structural enhancement ensures the case can withstand the lifting forces without damaging the cover.
2Strength
If holes are formed on the cover for fixing purposes, then the cover can be securely attached, but the available area for vacuum adsorption is reduced
Solution Approach 1:
The vacuum pad adsorption function is extracted from the cover and relocated to the case. This allows the cover to be equipped with fixation holes for secure attachment without compromising the vacuum adsorption area, as the adsorption region is now located on the case where holes are not needed for cover fixation.
3Power
If the battery module contains multiple batteries, then power and capacity requirements are met, but the weight increases making manual handling difficult
Solution Approach 1:
Manual mechanical lifting is replaced with a vacuum pad-based lifting system. The vacuum pad utilizes atmospheric pressure to lift the heavy battery module, eliminating the need for manual handling and enabling efficient transport of high-power, heavy modules containing multiple batteries.
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
Enables reliable and efficient transportation of battery modules using vacuum pads without damage, improving installation speed and accuracy by distributing the weight evenly and preventing disconnection during lifting.
Implementation Method 1
a vacuum pad adsorption region 7 which can be adsorbed by a vacuum pad P
Implementation Method 2
adsorbed by a vacuum pad through a vacuum atmosphere
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
According to one embodiment, a battery module includes a plurality of batteries and a module housing. The module housing accommodates the plurality of batteries. The module housing is configured by connecting a plurality of cases in a first direction. At least one of the plurality of cases includes a vacuum pad adsorption region which is on an end surface in a second direction intersecting the first direction and on which a vacuum pad is adsorbable.