Chamfered Battery Module Covers for Damage-Free Assembly
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Solution Overview
Problem
The assembly process of battery modules often results in damage to internal configurations due to friction or impact between the cell stack and the module housing, and the tight component tolerances in battery modules for electric vehicles make assembly challenging and reduce production yield.
Innovation Solution
A battery module design featuring a cell assembly with electrode leads protruding in the front and back directions, a bus bar assembly with a plate-shaped body, and an inner cover with chamfers on its outer peripheral portion, along with a coupling portion for the bus bar frame, which minimizes interference and facilitates smooth assembly by reducing friction and allowing for easier mounting and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If tight assembly tolerance is used to increase energy density, then energy density is improved, but assembly difficulty increases and production yield decreases
Solution Approach 1:
Chamfers are pre-formed on the inner cover and housing components before final assembly. This preliminary action creates built-in clearance and guidance features that compensate for tolerance variations, enabling smooth assembly while maintaining tight overall tolerances for high energy density.
Solution Approach 2:
The chamfer geometry (angle, depth, and shape) is optimized to transform the assembly interface characteristics. By changing the local geometric parameters at the mating surfaces, the design accommodates position errors and friction issues without compromising the overall tight tolerance requirements for energy density.
2Quantity of substance
If tight assembly tolerance is used to increase energy density, then energy density is improved, but production yield decreases
Solution Approach 1:
Chamfers are pre-formed on the inner cover and housing components before final assembly. This preliminary action creates built-in clearance and guidance features that compensate for tolerance variations, enabling smooth assembly while maintaining tight overall tolerances for high energy density.
Solution Approach 2:
The chamfer design converts potentially harmful friction and impact forces during assembly into beneficial guidance and cushioning effects. The chamfered surfaces guide components into proper alignment and reduce impact stresses, transforming assembly difficulties into assembly advantages that improve yield.
3Ease of manufacture
If chamfered inner cover and housing are used to prevent damage during assembly, then assembly ease is improved, but manufacturing complexity increases
Solution Approach 1:
The chamfering operation is applied locally only to specific mating surfaces of the inner cover and housing, rather than to entire components. This segmented approach adds minimal complexity only where needed for assembly, while keeping the rest of the component design simple and manufacturable.
Data Source
AI summary
A battery module minimizes damage to internal configurations generated in an assembly process. The battery module includes a cell assembly provided with an electrode lead and a plurality of secondary batteries stacked; a bus bar assembly provided with a bus bar frame located on a front or rear of the cell assembly, and a bus bar mounted on an outer surface of the bus bar frame; and an inner cover provided with a plate portion located on an outer side of the cell assembly, formed in a plate shape and formed with a chamfer on an outer peripheral portion and a coupling portion coupled to one end portion of the body portion of the bus bar frame on a part of the outer peripheral portion of the plate portion.