Battery Module Lower Case Forging for Delta Fin Accommodation
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Solution Overview
Problem
Conventional pouch-type secondary battery cells with delta fin portions pose challenges in manufacturing battery modules, as they occupy more space and can cause wrinkling or cracking when accommodated, reducing energy density and requiring new manufacturing methods to consider these protrusions.
Innovation Solution
A method involving extrusion molding and forging operations to create a case for battery modules, with a cooling plate and sidewall member integration, forming accommodation grooves that prevent wrinkling and cracking by ensuring a radius of curvature of 0.2 mm or less and a depth of 60% or less of the cooling plate's thickness, allowing for efficient accommodation of delta fin portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If accommodation grooves are formed with conventional punching methods, then the manufacturing process is simple, but wrinkling and cracking occur reducing reliability
Solution Approach 1:
The invention changes the geometric parameters of the punch tool, specifically using a punch with a vertically provided edge at the lower end and a radius of curvature of 0.2 mm or less. This parameter change in the tool geometry enables the formation of accommodation grooves that prevent wrinkling and cracking without requiring complex manufacturing processes.
Solution Approach 2:
The invention segments the manufacturing process into distinct operations: extrusion molding to form the cooling plate member and sidewall member, followed by a separate forging operation to form the accommodation grooves. This segmentation allows each process to be optimized independently, maintaining ease of manufacture while achieving high reliability.
2Quantity of substance
If the radius of curvature of the accommodation groove is large, then the manufacturing process is easier, but the delta fin portion cannot be properly accommodated reducing energy density
Solution Approach 1:
The invention specifies precise parameter ranges: radius of curvature of 0.2 mm or less and depth of 60% or less of the cooling plate member thickness. These parameter changes enable proper accommodation of the delta fin portion while maintaining manufacturability through standardized forging processes.
3Quantity of substance
If the accommodation groove depth is increased to fully accommodate the delta fin portion, then energy density improves, but the cooling plate member structural integrity is compromised
Solution Approach 1:
The invention optimizes the groove depth parameter to 60% or less of the cooling plate member thickness. This parameter setting achieves a balance where the delta fin portion is properly accommodated for high energy density while maintaining sufficient material thickness to preserve the structural integrity and strength of the cooling plate member.
4Productivity
If the cooling plate member and sidewall member are manufactured separately and assembled, then manufacturing flexibility is improved, but the connection portion becomes complex reducing productivity
Solution Approach 1:
The invention merges the cooling plate member and sidewall member into a single integrally formed component through extrusion molding. This consolidation eliminates the need for separate assembly operations and complex connection portions, directly improving manufacturing efficiency and productivity.
Solution Approach 2:
While the cooling plate member and sidewall member are integrally formed, the invention segments the subsequent processing by using a dedicated forging operation to form the accommodation grooves. This segmentation allows the integral structure to maintain manufacturing simplicity while enabling precise groove formation for proper delta fin accommodation.
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 method enhances energy density by securely accommodating more secondary battery cells while preventing wrinkling and cracking, ensuring a robust and efficient manufacturing process for battery modules.
Implementation Method 1
an extrusion molding operation in which a metal material is extruded to mold a cooling plate member and a sidewall member of the battery module
Implementation Method 2
a forging operation in which an internal surface of the cooling plate member is pressed with a punch, having an edge of a lower end provided vertically, to form an accommodation groove
Data Source
AI summary
A method for manufacturing a lower case of a battery module includes an extrusion molding operation in which a metal material is extruded to mold a cooling plate member and a sidewall member of a battery module; a forging operation in which an internal surface of the cooling plate member is pressed with a punch, having an edge of a lower end provided vertically to form an accommodation groove; and a forming operation in which an embossed piece, protruding to an external surface of the cooling plate member by forming the accommodation groove, is removed.