Stepped Battery Module Frame for Compact Cooling Assembly
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Solution Overview
Problem
Existing battery modules have inefficiencies in space utilization and thermally conductive resin usage due to the design of the frame member, leading to increased size, weight, and resin consumption.
Innovation Solution
A battery module design featuring a U-shaped or L-shaped frame with a stepped part and a protrusion on the battery cell, allowing for reduced clearance and optimized space utilization, along with a thermally conductive resin layer for heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional mono frame with uniform thickness is used to accommodate the battery cell stack, then the frame provides sufficient structural support and clearance for assembly, but the space utilization rate decreases and the amount of thermally conductive resin used increases
Solution Approach 1:
The frame member is designed with non-uniform thickness, featuring a first portion with greater thickness and a second portion with lesser thickness. This local variation in structural properties allows the frame to provide sufficient support where needed while minimizing material usage and clearance requirements in other areas, thereby improving space utilization and reducing thermally conductive resin consumption.
Solution Approach 2:
The frame member is divided into distinct portions with different thickness characteristics - a first portion with greater thickness and a second portion with lesser thickness. This segmentation allows each portion to be optimized for its specific functional requirements, resolving the contradiction between structural support and space efficiency.
2Ease of manufacture
If the clearance between the battery cell stack and the mono frame is increased to facilitate stable horizontal assembly, then the assembly process is stabilized, but the amount of thermally conductive resin required increases
Solution Approach 1:
The frame member provides different clearance characteristics at different locations through its non-uniform thickness design. The first portion with greater thickness provides adequate clearance for stable assembly, while the second portion with lesser thickness minimizes the clearance needed, thereby reducing the amount of thermally conductive resin required.
3Manufacturing precision
If the height of the mono frame is increased to account for maximum battery cell stack height and assembly tolerance, then the assembly tolerance is accommodated, but unnecessary wasted space occurs
Solution Approach 1:
The non-uniform thickness design of the frame member allows for localized accommodation of assembly tolerances in the first portion with greater thickness, while the second portion with lesser thickness minimizes overall frame height and reduces wasted space. This resolves the contradiction between tolerance accommodation and space 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 design enhances space utilization and reduces the amount of thermally conductive resin needed, leading to a more compact and efficient battery module with improved cooling efficiency.
Implementation Method 1
A thermally conductive resin layer (not shown) may be formed between the battery cell stack 12 and the mono frame 20. 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 one embodiment of the present disclosure comprises a battery cell stack in which a plurality of battery cells are stacked, a first frame member accommodating the battery cell stack and having an open upper part, and a second frame member covering the battery cell stack from an upper portion of the first frame member. A surface of the battery cell stack extending parallel to the stacking direction of the plurality of battery cells is attached to the bottom part of the first frame member. A stepped part is formed on one side of the bottom part of the first frame member, and a protrusion part of the battery cell protrudes toward the stepped part.