Single-Layer Battery Module Frame Design for Height Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules have a high overall height, making them difficult to install under the floor of electric vehicles, and require additional components and higher costs due to separate bus bars and lack of protection for control units from external forces.
Innovation Solution
A battery module with a frame that holds battery cells in a single layer, using a conductive frame as a bus bar and positioning the control unit at the center to reduce height and eliminate the need for separate bus bars, while also enhancing stability by shielding the control unit from external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are stacked vertically in a conventional battery module, then the battery module can accommodate multiple battery cells, but the overall height increases making it difficult to install under the floor of electric vehicles
Solution Approach 1:
The patent transitions from vertical stacking (height direction) to horizontal arrangement (length/width directions) of battery cells within the frame. By arranging cells in rows and columns rather than stacking them vertically, the design redistributes the spatial occupation from the height dimension to the horizontal plane, thereby reducing overall height while maintaining the quantity of battery cells.
Solution Approach 2:
The frame structure is designed to serve dual functions: mechanical support for battery cells and electrical connection (bus bar function). This merging of structural and electrical functions eliminates the need for separate bus bars and enables a compact single-layer arrangement that reduces height while accommodating multiple cells.
2Reliability
If separate bus bars are used to electrically connect battery cells, then reliable electrical connection is achieved, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The frame is designed to integrate both mechanical support and electrical connection functions. The conductive frame members directly electrically connect the battery cells while providing structural support, eliminating the need for separate bus bars and reducing the total component count while maintaining reliable electrical connections.
Solution Approach 2:
The frame structure is designed as a multi-functional component that simultaneously serves as mechanical support, electrical conductor (bus bar), and structural framework. This universal design allows a single component to perform multiple functions that traditionally required separate parts, thereby reducing complexity and manufacturing cost.
3Ease of operation
If the control unit is positioned outside the frame structure, then ease of installation is improved, but the control unit is vulnerable to external forces and stability is reduced
Solution Approach 1:
The control unit is integrated within the frame structure rather than being mounted externally. This integration provides inherent mechanical protection against external forces while maintaining accessibility for installation and maintenance. The frame acts as a protective enclosure that shields the control unit without complicating the installation process.
Data Source
AI summary
Disclosed are a battery module and a battery pack including the same. The battery module includes a frame; and a plurality of battery cells disposed at the frame, and the plurality of battery cells are arranged in a single layer with respect to the frame.