Battery Module Buffer Layout for Swelling-Resistant Cooling

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Solution Overview

Problem

Conventional battery modules face damage due to swelling of battery cells, particularly at the outermost sides, leading to potential electrolyte leakage and degraded performance, as the thermal resin fixes the lower ends while the outer cells are pushed outward, applying a large tensile force.

Innovation Solution

A battery module design featuring buffer spaces under the outermost cells and thermal resin under all other cells, with buffer pads on the inner case walls, reducing tensile force through air-filled spaces and resin stoppers to prevent damage during swelling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal resin is provided on the bottom surface of the module case to cool the battery cells, then cooling performance is improved, but the risk of damage to outermost battery cells increases due to tensile force during swelling

Engineering Contradiction:

Improvecooling performanceVSAvoiddamage risk to battery cells

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies different structural configurations to different locations within the module case. Specifically, the first battery cell group (outermost cells) is positioned with a first distance from the bottom surface, while the second battery cell group (inner cells) is positioned with a second distance, creating localized structural variations that address both cooling and damage prevention needs in different regions

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent pre-establishes a protective spatial arrangement by positioning the outermost battery cells at a greater distance from the bottom surface before swelling occurs. This predetermined spacing creates a buffer zone that absorbs the expansive force during swelling, preventing direct contact and potential damage between the thermal resin and the battery cells

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Quantity of substance

If battery cells are stacked inside the module case to achieve required capacity, then charge/discharge capacity is improved, but swelling causes outermost cells to be pushed outward leading to potential tearing

Engineering Contradiction:

Improvecharge/discharge capacityVSAvoidpouch case integrity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent creates different spatial environments for different battery cell groups. The outermost battery cells are positioned with a first distance from the bottom surface, while inner battery cells are positioned with a second distance, creating localized protective zones where the outermost cells have additional clearance to accommodate swelling without compromising pouch case integrity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent preemptively counteracts the swelling force by positioning the outermost battery cells at a greater distance from the bottom surface before swelling occurs. This preliminary spatial arrangement creates resistance against the outward pushing force during swelling, preventing the pouch case from being torn or damaged

Inventive Principle:

Principle #9Preliminary anti-action

3Stability of the object's composition

If outermost battery cells are pushed outward during swelling while lower end portions are fixed by thermal resin, then swelling is contained, but large tensile force is applied to pouch case increasing damage risk

Engineering Contradiction:

Improveswelling containmentVSAvoidtensile force on pouch case

Core Design Contradiction:

Stability of the object's compositionVSForce

Solution Approach 1:

The patent creates a differentiated spatial structure where outermost battery cells are positioned with a first distance from the bottom surface, while inner battery cells are positioned with a second distance. This local structural variation allows the outermost cells to have additional clearance that reduces the tensile force transmitted to the pouch case during swelling

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces a spatial buffer zone (the first distance) between the thermal resin and the outermost battery cells. This intermediary space acts as a cushion that absorbs and distributes the swelling force, reducing the direct tensile force applied to the pouch case while still containing the swelling within the module case

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively prevents cell damage by reducing tensile force on outermost cells, maintaining module dimensions, and ensuring cost-effectiveness by avoiding additional components, thus enhancing battery pack and vehicle performance.

Implementation Method 1

a thermal resin provided inside the module case, and configured to cool the plurality of battery cells

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4187693B1Battery module, and battery pack and vehicle that include same

Publication Date: 2026.01.28 LG ENERGY SOLUTION LTD

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AI summary

A battery module according to an embodiment of the present disclosure includes a plurality of battery cells, a module case in which the plurality of battery cells are accommodated, a thermal resin provided inside the module case, and configured to cool the plurality of battery cells, and buffer spaces facing each other with the thermal resin therebetween, and provided inside the module case.