Battery Module Frame With Vertical Cell Stack Insertion
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Solution Overview
Problem
The existing battery module assembly process is inefficient due to the need for large clearances between the battery cell stack and the frame, leading to potential damage and increased costs, and the use of guide films often results in breakage during insertion.
Innovation Solution
A battery module design featuring a frame member with inward-projected parts on the side surfaces, allowing vertical insertion of the battery cell stack, which includes inclined portions for guiding the stack into the frame without expanding the frame, thereby improving assembly speed and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large clearance is secured between battery cell stack and frame for stable horizontal assembly, then assembly stability is improved, but assembly efficiency deteriorates due to increased wasted space and slower insertion speed
Solution Approach 1:
The patent inverts the traditional horizontal assembly direction to vertical insertion. The battery cell stack is inserted vertically into the frame from the top, reversing the conventional assembly approach. This inversion eliminates the need for large clearances and guide films, enabling fast and accurate assembly while improving both assembly stability and efficiency simultaneously
Solution Approach 2:
The patent transitions from two-dimensional horizontal assembly to three-dimensional vertical insertion. By changing the assembly dimension from horizontal (X-axis) to vertical (Z-axis), the design achieves precise positioning without requiring large clearances, thereby improving both reliability and productivity
2Manufacturing precision
If guide film is used to minimize assembly tolerance, then positioning precision is improved, but device complexity and cost increase due to film replacement requirements
Solution Approach 1:
The patent removes the guide film component entirely from the assembly system. Instead of using a separate film element that requires replacement, the positioning function is integrated directly into the frame structure through vertically-oriented positioning protrusions that guide the battery cell stack during vertical insertion
Solution Approach 2:
The frame structure provides self-guiding functionality through its vertically-oriented positioning protrusions. The positioning features are built into the frame itself, eliminating the need for external guide films and enabling the assembly system to guide itself during vertical insertion without additional components
3Device complexity
If horizontal assembly is used with mono frame, then structural simplicity is maintained, but assembly speed is reduced due to clearance requirements
Solution Approach 1:
The patent inverts the assembly direction from horizontal to vertical. The battery cell stack is inserted vertically into the frame from the top, reversing the conventional horizontal assembly approach. This simple directional change eliminates clearance issues and dramatically increases inserting speed while maintaining frame structure simplicity
Solution Approach 2:
The patent changes the key parameter of assembly direction from horizontal to vertical. This parameter change transforms the assembly process from a clearance-dependent horizontal insertion to a clearance-independent vertical insertion, thereby increasing inserting speed without complicating the frame structure
Data Source
AI summary
The battery module includes a battery cell stack in which a plurality of battery cells are stacked, a frame member for housing the battery cell stack and having an opened upper part, and an upper plate for covering the battery cell stack on an upper part of the frame member, wherein the frame member comprises two side surface parts facing each other and a bottom part connecting the two side surface parts, and wherein a projected part projected inward is formed in the side surface part.