Battery Block with Resin Partition Walls
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Solution Overview
Problem
Existing battery blocks face challenges in preventing high-temperature gas from one faulty battery from affecting other batteries due to gaps between the metallic battery holder and terminal plates, which allows gas to flow and potentially cause overheating.
Innovation Solution
A battery block design featuring a battery holder made of curable resin with integral partition walls and extending portions that surround the safety valve area, eliminating the need for insulating plates and allowing terminal plates to be in close contact, thereby minimizing gas flow between batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic battery holder is used with insulating plates, then electrical insulation is achieved, but large gaps are formed between the terminal plate and holder, allowing high-temperature gas to flow between batteries
Solution Approach 1:
The battery holder is constructed from composite material consisting of heat-resistant resin and inorganic filler (such as aluminum hydroxide or magnesium hydroxide). This composite structure provides both electrical insulation properties and high-temperature resistance, eliminating the need for separate insulating plates while maintaining structural integrity at elevated temperatures and preventing gas flow paths.
Solution Approach 2:
The functions of electrical insulation and structural support are merged into a single battery holder component made of heat-resistant composite material. This integration eliminates the need for separate insulating plates and reduces the number of parts, while the integral structure prevents gap formation that would allow gas flow between batteries.
2Ease of manufacture
If the battery accommodating part is made slightly larger than the battery diameter, then easy battery installation is achieved, but gaps are formed that enable gas to axially flow between batteries
Solution Approach 1:
The battery holder features localized extending portions that protrude toward the battery axial ends at specific locations. These extending portions create localized restriction zones that prevent gas flow while maintaining adequate clearance in other areas for easy battery installation. The partition walls also provide localized separation to block gas flow paths between adjacent batteries.
Solution Approach 2:
The battery holder incorporates flexible-like extending portions made of heat-resistant composite material that can accommodate minor dimensional variations in batteries during installation, while still maintaining sufficient restriction to prevent gas flow. The material's properties allow for slight deformation during assembly while providing rigid gas flow prevention when installed.
3Object-affected harmful factors
If adhesive is applied between insulating plate and battery to fill gaps, then gas flow is reduced, but the structure becomes more complex and less reliable
Solution Approach 1:
The design extracts and eliminates the need for separate insulating plates and adhesive materials by integrating all necessary functions into the battery holder itself. The heat-resistant composite material provides inherent insulation properties, and the extending portions with partition walls provide built-in gas flow restriction, removing the need for additional components and assembly steps.
Solution Approach 2:
The battery holder structure is designed to self-restrict gas flow through its integral extending portions and partition walls, without requiring external adhesive materials or additional insulating components. The structure serves its own gas flow prevention function through its geometric design and material properties.
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 design effectively reduces the influence of high-temperature gas from a faulty battery on other batteries by preventing gas flow and maintaining the shape of the battery holder even at high temperatures, ensuring the safety and reliability of the battery block.
Implementation Method 1
a battery holder that is made of a curable resin and has a plurality of accommodating parts into which axial one end portions of the cylindrical batteries are inserted
Implementation Method 2
an extending portion that extends on the first end surface so as to surround a part of the first end surface on which the safety valve is disposed and that is formed integrally with the partition wall
Data Source
AI summary
A battery block includes a plurality of cylindrical batteries, a battery holder having a plurality of accommodating parts into which axial one end portions of the cylindrical batteries are inserted, and a pair of terminal plates, that connect the cylindrical batteries in parallel. Each of the accommodating parts includes the partition wall formed along an outer peripheral surface of cylindrical battery, an extending portion that extends on the first end surface so as to surround a part of the first end surface on which the safety valve is disposed and is formed integrally with the partition wall, and an opening that exposes the part of the first end surface on which the safety valve is disposed.