Battery Module Connector Moisture Barrier for Humid Conditions
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Solution Overview
Problem
Moisture ingress into battery modules can lead to short circuits and damage the sensing function of connectors, posing a risk of ignition, especially under high temperature and high humidity conditions.
Innovation Solution
A battery module structure featuring a moisture barrier film formed between the connector and the module frame, which guides and discharges moisture outside the module through an inclined extension portion and a passage between the insulating cover and end plate, preventing moisture from reaching the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is formed in an open form to facilitate automated assembly of FFC, then the ease of manufacture is improved, but moisture can easily ingress into the connector causing short circuits and reliability deterioration
Solution Approach 1:
A moisture barrier member is introduced as an intermediary component between the connector and the module frame. This barrier member selectively blocks moisture ingress while allowing the connector to maintain its open, easily-assembled structure. The barrier member acts as a mediator that protects the connector from moisture without interfering with the automated FFC assembly process.
Solution Approach 2:
The moisture barrier member is implemented as a thin film or shell structure that conforms to the connector geometry. This flexible barrier effectively seals the connector opening against moisture while maintaining the structural integrity and electrical functionality of the connector. The thin film approach allows easy integration into the existing connector design without requiring complex structural modifications.
2Extent of automation
If the connector has an open upper side structure, then automated robot arm assembly of FFC is enabled, but moisture condensation on the module frame can flow directly into the connector causing short circuits
Solution Approach 1:
The moisture barrier member serves as a protective intermediary positioned between the moisture source (condensation on module frame) and the vulnerable connector. It selectively blocks the harmful moisture while allowing the automated assembly process to proceed unchanged, as the barrier is integrated in a way that does not interfere with robot arm access or FFC connection.
Solution Approach 2:
The moisture blocking function is extracted as a separate, dedicated component (moisture barrier member) rather than being integrated into the connector structure itself. This separation allows the connector to maintain its open, automated-friendly design while the extracted barrier function provides selective protection against moisture ingress.
3Reliability
If moisture proofing structures are added to protect the connector, then reliability is improved, but the device complexity increases
Solution Approach 1:
The moisture proofing is achieved using a thin film moisture barrier member that is structurally simple yet functionally effective. This approach avoids complex multi-component assemblies or bulky protective structures, maintaining device simplicity while providing reliable moisture protection. The thin film can be easily integrated into the existing module assembly process.
Solution Approach 2:
The moisture barrier member is designed as a simple intermediary component that fits between existing structural elements (connector and module frame). This intermediary approach adds minimal complexity compared to redesigning the entire connector or module structure, as it leverages existing spaces and interfaces for moisture protection.
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
Effectively prevents moisture ingress, safeguarding the connector's sensing function and preventing short circuits, ensuring safe operation under humid conditions.
Implementation Method 1
A battery module structure featuring a moisture barrier film formed between the connector and the module frame, which guides and discharges moisture outside the module
Implementation Method 2
guides and discharges moisture outside the module through an inclined extension portion and a passage
Data Source
Figure 1
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AI summary
A battery module according to one embodiment of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked; a module frame for accommodating the battery cell stack; a busbar frame formed at both ends of the battery cell stack, respectively; a connecting portion that connects the busbar frames arranged at both ends, respectively, and is formed of a flexible flat cable (FFC); and a connector formed on the busbar frame and coupled to the connecting portion, wherein a film portion is formed between the connector and the upper side portion of the module frame.