Stepped U-Shaped Battery Module Frame for Resin and Cooling Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face inefficiencies in space utilization and excessive use of thermally conductive resin due to the design of the frame member surrounding the battery cell stack, which results in unnecessary clearance and wasted space during assembly.
Innovation Solution
A U-shaped frame with a stepped portion is used to accommodate the battery cell stack, reducing the gap between the cells and the frame, and a thermally conductive resin layer is applied between the frame and the cells, minimizing resin usage and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional mono frame with opened front and rear surfaces is used to accommodate the battery cell stack, then the battery module can be assembled horizontally, but excessive clearance is generated between the battery cell stack and the frame, leading to increased use of thermally conductive resin and wasted space
Solution Approach 1:
The frame is divided into a bottom frame and a top frame that are positioned at different heights, creating a stepped structure. This segmentation allows the frame to better accommodate the battery cell stack while reducing excessive clearance and minimizing thermally conductive resin usage.
Solution Approach 2:
The frame structure transitions from a single-plane design to a multi-level stepped structure by introducing vertical dimensionality. The bottom frame and top frame are positioned at different heights, creating a three-dimensional configuration that reduces clearance while maintaining assembly feasibility.
2Ease of manufacture
If the mono frame height is designed to be large to accommodate assembly tolerance, then horizontal assembly can be performed, but unnecessary wasted space occurs in the battery module
Solution Approach 1:
The frame height tolerance is segmented between the bottom frame and top frame, which are positioned at different heights. This allows assembly tolerance to be distributed across multiple components rather than requiring excessive height in a single frame structure.
Solution Approach 2:
The frame structure utilizes vertical dimensionality with the top frame positioned higher than the bottom frame. This multi-level configuration accommodates assembly tolerance in the vertical direction while maintaining a compact overall battery module volume.
3Ease of manufacture
If sufficient clearance is secured between the battery cell stack and the mono frame for stable horizontal assembly, then assembly can be performed, but the thermally conductive resin layer becomes thicker than necessary, reducing cooling efficiency
Solution Approach 1:
The frame is segmented into bottom and top portions at different heights, creating a stepped structure that provides stable assembly support while minimizing the thickness of the thermally conductive resin layer required for thermal management.
Solution Approach 2:
The stepped frame structure introduces vertical dimensionality, positioning the top frame higher than the bottom frame. This three-dimensional configuration provides stable assembly while reducing the resin layer thickness in the horizontal direction, thereby improving cooling efficiency.
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 U-shaped frame design enhances space utilization by reducing assembly tolerance and minimizing thermally conductive resin usage, leading to improved cooling efficiency and reduced waste space, while maintaining structural integrity and heat transfer capabilities.
Implementation Method 1
The thermally 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 according to an embodiment of the present disclosure comprises: a battery cell stack in which a plurality of battery cells are stacked; a U-shaped frame accommodating the battery cell stack and having an open upper portion; and an upper plate covering the battery cell stack at the open upper portion of the U-shaped frame. A surface of the battery cell stack extending parallel to a stacking direction of the plurality of battery cells is mounted on a bottom portion of the U-shaped frame. A stepped portion is formed on one side of the bottom portion of the U-shaped frame, and at least one of the battery cells includes a protruding portion protruding toward the stepped portion. The stepped portion may be formed by a bent portion of the bottom portion of the U-shaped frame.