Battery Module Buffer Space Layout for Pouch Cell Swelling

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Solution Overview

Problem

Conventional battery modules face damage due to swelling of battery cells, which leads to potential tearing of the pouch case and leakage of electrolytic solution, compromising insulation and performance.

Innovation Solution

Incorporation of buffer spaces filled with air between the thermal resin and the module case, along with buffer pads on the inner walls, to absorb and reduce the tensile force applied to the outermost battery cells during swelling, thereby preventing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If battery cells are stacked inside the module case with thermal resin on the bottom surface, then cooling performance is improved, but the risk of pouch case tearing increases during swelling

Engineering Contradiction:

Improvecooling performanceVSAvoidpouch case integrity

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent applies beforehand cushioning by providing buffer spaces filled with buffer material (such as foam or air) between the thermal resin and the lower ends of the battery cells. These buffer spaces are pre-configured to absorb swelling forces before they can transmit to the pouch case, thereby preventing tearing while maintaining cooling contact through the thermal resin.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If buffer spaces are added to prevent pouch case tearing, then battery cell protection is improved, but device complexity increases

Engineering Contradiction:

Improvebattery cell protectionVSAvoidmodule structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the buffer function with the existing thermal resin structure by integrating buffer spaces directly into the thermal management system. The buffer material is incorporated within the module case structure, combining protective and thermal functions in a unified design that minimizes additional complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal resin structure serves multiple functions: it provides thermal conduction for cooling, structural support for battery cells, and when integrated with buffer spaces, it also provides swelling protection. This multi-functionality reduces the need for separate protective components, thereby limiting complexity increase.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution effectively reduces the risk of damage to battery cells during swelling, maintaining module dimensions and preventing tearing without additional components, ensuring cost-effectiveness and improved 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

PatentUS20230299405A1Battery module, and battery pack and vehicle that include same

Publication Date: 2023.09.21 LG ENERGY SOLUTION LTD

AI summary

A battery module 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.