Integral Battery Frame With Symmetric Attachment And Cooling
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Solution Overview
Problem
Existing battery module packaging technologies are complex, requiring numerous parts and components, making assembly challenging, particularly for high energy density batteries like LiPo, and complicating the integration of cooling systems, which is difficult to modify without significant redesign and increased costs.
Innovation Solution
A simplified frame assembly design featuring integral frames with attachment and cooling features, allowing for symmetric alignment and attachment of battery cells, and a modular cooling system using thermally conductive corrugated sheets for efficient heat transfer, reducing the number of parts and complexity in assembly and cooling integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging technology with multiple plastic frames and supports is used, then battery cells can be captured and assembled into modules, but the assembly process becomes complex requiring numerous parts and fasteners
Solution Approach 1:
The patent combines multiple separate components (frames, supports, and cell holders) into a single integrated frame structure. The frame includes integrated features such as cooling channels, alignment features, and cell retention structures that were previously separate parts, thereby reducing the total number of components and simplifying assembly while maintaining reliable battery cell capture and module assembly
Solution Approach 2:
The frame structure is designed to perform multiple functions simultaneously: it provides structural support for battery cells, integrates cooling channels for thermal management, includes alignment features for precise cell positioning, and incorporates retention mechanisms for cell securement. This multi-functional design eliminates the need for separate dedicated components for each function, reducing overall system complexity
2Ease of manufacture
If molding plastic flanges or features around battery cells is used, then cell packaging can be achieved, but material and labor costs increase along with potential cell damage
Solution Approach 1:
The patent separates the packaging function from the cell itself by using an external frame structure that houses the cells, rather than molding features directly onto or around the cells. The frame is designed as a modular assembly that can be manufactured separately and then assembled with the cells, avoiding the need for complex molding operations on the cells themselves and reducing both material waste and labor-intensive molding, testing, and inspection processes
3Ease of operation
If alignment features are integrated into frames, then assembly process can be aided, but the integration becomes cumbersome due to the number of parts
Solution Approach 1:
Alignment features are integrated directly into the frame structure itself rather than being separate components. The frame includes built-in alignment ribs, guide slots, or geometric features that automatically align battery cells during assembly, eliminating the need for separate alignment devices or complex multi-step alignment procedures while maintaining ease of assembly operation
4Temperature
If cooling systems are incorporated into battery modules, then thermal management is provided, but the assembly complexity increases and modifications require significant redesign
Solution Approach 1:
Cooling channels are integrated directly into the frame structure, combining the thermal management function with the structural support function. The frame includes embedded cooling passages that can be molded or machined as part of the frame itself, allowing coolant flow paths to be built into the assembly rather than requiring separate cooling plates or heat sinks, thereby reducing overall assembly complexity while providing effective thermal management
Solution Approach 2:
The frame structure is designed to simultaneously provide mechanical support for battery cells and serve as the cooling system conduit. The same frame components that hold and align cells also contain the cooling channels, creating a multi-functional element that reduces the number of separate systems needed and makes modifications easier since the cooling infrastructure is already part of the universal frame design
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 solution enables more efficient and cost-effective assembly of battery modules with enhanced thermal management, allowing for versatile cooling configurations and minimal tooling changes, while maintaining structural and mechanical integrity, thus supporting high volume manufacturing and flexible power and energy output.
Implementation Method 1
a cooling member having a first side and a second side, the first side attached to the cooling face of the first frame and covering the first opening, the second side attached to the cooling face of the second frame and covering the second opening
Data Source
AI summary
A frame member for housing a battery cell, frame assembly and frame/battery cell assembly made therefrom, as well as respective methods of making the same, are disclosed. A frame member for housing a battery cell includes an integral frame having a peripheral wall, the peripheral wall having an attachment face and an opposed cooling face, and an attachment feature located on the attachment face and a complementary attachment feature located on the attachment face that is symmetrically opposed to the attachment feature about a plane of symmetry of the frame, the peripheral wall defining an opening that is configured to matingly receive a battery cell therein. A pair of frame members having a cooling member placed therebetween and attached to the respective attachment faces comprises a frame assembly. A frame/battery cell assembly includes a pair of frame assemblies having at least one battery cell placed therebetween.