Expandable Battery Module Housing for Variable Cell Assembly Sizes
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Solution Overview
Problem
The manufacturing cost of battery modules and packs is increased due to the need for different-sized module housings to accommodate secondary batteries of varying sizes, requiring design modifications and additional production equipment.
Innovation Solution
A battery module design featuring a module housing with at least two frames that can adjust their length to fit different-sized cell assemblies, allowing for a single housing type to be used across various sizes, and frames that can accommodate each other to minimize production needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different-sized module housings are used to accommodate secondary batteries of varying sizes, then the battery module can adapt to different capacity requirements, but the manufacturing cost increases due to design modifications and additional production equipment
Solution Approach 1:
The patent applies universality by designing a single standardized module housing that can accommodate secondary batteries of various sizes through internal configuration changes rather than requiring different housing designs. The housing serves multiple functions across different battery size requirements, eliminating the need for separate housing designs for each battery size category.
Solution Approach 2:
The patent implements the nested doll principle by allowing smaller module housings to be placed within larger module housing spaces. The standardized housing design enables nested arrangements where modules of different sizes can be combined in a single battery pack, optimizing space utilization while maintaining manufacturing simplicity.
2Adaptability or versatility
If multiple sizes of module housings are produced to fit various secondary battery sizes, then different capacity requirements are met, but production equipment must be changed and manufacturing complexity increases
Solution Approach 1:
The standardized module housing design enables a single production line to manufacture housings that can accommodate various battery sizes, eliminating the need for multiple specialized production equipment sets. The universal housing serves different capacity requirements through internal configuration rather than external design variations.
Solution Approach 2:
The patent applies parameter changes by maintaining constant external housing dimensions while varying internal parameters such as the number and arrangement of battery slots. This allows the same housing mold and production equipment to produce configurations suitable for different battery capacities without equipment modification.
3Ease of manufacture
If standardized module housings are used for all secondary battery sizes, then manufacturing cost is reduced, but the housing may not optimally fit all battery configurations
Solution Approach 1:
The nested doll principle is applied by designing the standardized housing with internal nesting capabilities that allow precise accommodation of different battery sizes. Smaller batteries can be nested within the standardized housing structure with precise fitting, while larger batteries can utilize the full housing capacity, maintaining optimal fit across all configurations.
Solution Approach 2:
The patent applies local quality by maintaining uniform external housing dimensions for manufacturing simplicity while introducing variable internal features such as adjustable dividers, removable partitions, or configurable mounting structures. These local internal variations provide precise fitting for different battery sizes without compromising the standardized external housing design.
Data Source
AI summary
The present disclosure relates to a battery module with reduced manufacturing cost and a battery pack comprising the same. To achieve the above-described object, the battery module according to the present disclosure includes a cell assembly including a plurality of secondary batteries, and a module housing in which the cell assembly is received, wherein the module housing includes at least two frames capable of changing a length of the module housing according to a size of the cell assembly.