Double-Frame Battery Module With Side Members for Swelling Control
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Solution Overview
Problem
Existing battery modules face issues with deformation due to cell swelling and temperature deviation, leading to increased weight and height, as well as reduced performance and lifespan, particularly in high-integration battery stacks.
Innovation Solution
A battery module design featuring a double frame structure with side members and a polymer resin layer to manage swelling and temperature deviation, using a first and second frame with side portions and a side member to absorb swelling and interrupt heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of battery cells are stacked at high integration to improve capacity and output, then the battery module's energy density increases, but temperature deviation between cells deepens and swelling occurs
Solution Approach 1:
The battery module is divided into multiple battery stacks, with each stack containing a specific number of battery cells (e.g., 3-5 cells per stack). This segmentation allows for better thermal management within each stack, reducing temperature deviation between cells while maintaining high overall capacity through parallel connection of multiple stacks.
Solution Approach 2:
A cooling plate is introduced as an intermediary component between battery stacks. The cooling plate includes cooling channels that facilitate heat dissipation from the battery cells, particularly addressing thermal issues in high-integration configurations where cells are densely packed.
2Ease of manufacture
If battery cells are stacked horizontally to form a battery module, then assembly is simplified, but sufficient clearance must be secured leading to wasted space and increased module height
Solution Approach 1:
The patent transitions from horizontal stacking to vertical stacking of battery cells within the module. This dimensional change allows for more efficient space utilization, reducing the required clearance and module height while maintaining assembly feasibility through the structured stack configuration.
3Strength
If frame thickness is increased to withstand swelling pressure from high-integration battery stacks, then structural stability improves, but weight and height of the module increase
Solution Approach 1:
The frame structure is segmented into multiple components including side frames, end plates, and support ribs distributed throughout the module. This segmentation allows the frame to distribute and withstand swelling pressures from battery cells more efficiently, maintaining structural stability with thinner overall frame thickness, thereby reducing weight.
4Quantity of substance
If battery cells are densely stacked to improve capacity, then space utilization increases, but temperature deviation between cells deepens reducing performance and lifespan
Solution Approach 1:
Battery cells are organized into multiple stacks with controlled cell counts per stack (3-5 cells), creating natural thermal zones that facilitate heat management. This segmentation maintains high cell density while ensuring temperature uniformity across the module, preserving performance and lifespan.
Solution Approach 2:
Cooling plates with integrated cooling channels serve as intermediaries between densely stacked battery cells. These plates facilitate efficient heat dissipation, maintaining temperature uniformity even in high-density configurations, thereby preserving battery reliability and extending lifespan.
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
The design effectively prevents structural deformation and temperature deviation, minimizing weight and height increases while enhancing performance and lifespan by absorbing swelling and reducing thermal disparities among cells.
Implementation Method 1
a side member (400) located between the first side portion (210) and the second side portion (310)
Implementation Method 2
the side member (400) located between the first side portion (210) and the second side portion (310)... interrupt heat transfer
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked, a first frame for covering a lower portion of the battery cell stack and a second frame for covering an upper portion of the battery cell stack. The first frame includes first side portions for covering both side surfaces of the battery cell stack. The second frame comprises second side portions for covering the first side portions, and wherein a side member is located between the first side portion and the second side portion.