Dual-Frame Battery Module for Swelling Rigidity and Space Use
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Solution Overview
Problem
Existing battery modules face challenges in maximizing space utilization and securing lateral rigidity without unnecessary weight increase, particularly due to the swelling of battery cells and excessive use of heat-conductive resin.
Innovation Solution
A battery module design featuring a dual-module frame structure with overlapping side surfaces and a heat-conductive resin layer, where the first and second module frames surround the battery cell stack, reducing clearance and minimizing resin usage while providing enhanced lateral rigidity through a U-shaped structure and adhesive or welding coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the mono frame is increased to withstand battery cell swelling, then the lateral rigidity is improved, but the weight of the battery module is unnecessarily increased
Solution Approach 1:
The mono frame is divided into two separate module frames (first and second) that are positioned at different heights. This segmentation allows each frame to be optimized for its specific function: the first frame provides lateral support against swelling while the second frame provides vertical support, eliminating the need for excessive thickness in a single monolithic frame.
Solution Approach 2:
Different regions of the frame structure are given different thicknesses and strengths based on their specific functional requirements. The first module frame has greater thickness for lateral rigidity to counteract swelling, while the second module frame has sufficient thickness for vertical support, avoiding uniform over-engineering throughout the entire frame structure.
2Ease of operation
If the height of the mono frame is designed to be large to accommodate assembly tolerance, then the horizontal assembly is stabilized, but an unnecessarily wasted space occurs
Solution Approach 1:
The frame height requirement is segmented into two independent components: the first module frame height is determined by battery cell stack height plus vertical tolerance, while the second module frame height is determined by assembly clearance requirements. This allows each frame to be minimized to its necessary dimension rather than requiring the entire frame to be oversized for both tolerances simultaneously.
Solution Approach 2:
The problem of accommodating both vertical and horizontal tolerances is solved by transitioning from a single-frame horizontal insertion approach to a two-frame vertical stacking approach. The first frame accommodates vertical battery cell stack dimensions, while the second frame provides the necessary clearance for assembly, effectively distributing tolerance accommodation across different spatial dimensions.
3Strength
If the thickness of the upper and lower surfaces of the mono frame is increased, then the swelling phenomenon is withstood, but the weight is unnecessarily increased
Solution Approach 1:
The first module frame is designed with increased thickness specifically in the regions that contact or are adjacent to the battery cell stack, where swelling forces are applied. The second module frame, which does not directly bear swelling loads, has sufficient but not excessive thickness. This localized reinforcement provides swelling resistance only where needed, minimizing overall weight.
4Volume of stationary object
If the space in the battery module becomes large, then the amount of heat-conductive resin layer used is increased more than necessary
Solution Approach 1:
The frame structure is segmented into two frames with different heights, allowing the first frame to be positioned closer to the battery cell stack and reducing the vertical space gap. This segmentation enables more efficient space utilization and reduces the volume of heat-conductive resin required to fill gaps between the frame and battery cells.
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
This design improves space utilization, maintains lateral rigidity without weight increase, and optimizes heat conduction, enhancing the energy density and overall efficiency of the battery module.
Implementation Method 1
a heat-conductive resin layer (not shown) may be formed between the battery cell stack 12 and the mono frame 20. The heat-conductive resin layer may serve to transfer heat generated from the battery cell stack to the outside of the battery module
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked; and a module frame for housing the battery cell stack. The module frame includes a first module frame having an opened upper part and a second module frame having an opened lower part. The first module frame includes a first side surface part, a second side surface part, and a bottom part for connecting the first side surface part and the second side surface part, wherein the second module frame includes a third side surface part, a fourth side surface part, and a ceiling part for connecting the third side surface part and the fourth side surface part. The first module frame and the second module frame surround the battery cell stack in a state where the first side surface part and the third side surface part are overlapped, and the second side surface part and the fourth side surface part are overlapped.