Integrated Battery Cell Frame With Firewall for Flame Spread Control
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Solution Overview
Problem
Conventional battery modules face challenges in manufacturing a cell frame with a uniform height corresponding to battery cells, leading to gaps that facilitate rapid flame spread between adjacent cells due to heat accumulation and inefficient heat removal.
Innovation Solution
A one-piece, vertically symmetrical cell frame with integrated support ribs and a firewall part made of potting resin surrounds battery cells, preventing fire spread by filling the entire cell insertion space with a flame-retardant material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cell frame is manufactured as a single integrated component, then manufacturing precision is improved and gaps are eliminated, but device complexity increases due to the need for integrated support ribs and firewall structures
Solution Approach 1:
The cell frame is designed as a single integrated component that combines the frame structure, support ribs, and firewall into one unified part. This merging eliminates gaps between separate components while providing structural support and fire prevention functions through integrated design elements.
Solution Approach 2:
The integrated cell frame incorporates segmented support ribs that divide the internal space to provide structural reinforcement and facilitate heat dissipation. These internal segments are formed within the single-component frame structure to maintain both integrity and functional division.
2Reliability
If a firewall part surrounds each battery cell, then reliability is improved by preventing fire spread, but manufacturing precision requirements increase to ensure proper filling and curing
Solution Approach 1:
A firewall part made of flame-retardant material is introduced as an intermediary substance that fills the space between battery cells within the integrated frame. This material acts as a barrier to prevent fire spread while being injected and cured in place to ensure proper formation without requiring complex assembly precision.
Solution Approach 2:
The firewall part utilizes materials with specific flame-retardant properties and undergoes a curing process that transforms the material from a liquid or semi-liquid state to a solid barrier. This parameter change allows the firewall to be formed in situ with proper adhesion and structural integrity.
3Ease of manufacture
If the cell frame is designed with vertical symmetry, then ease of manufacture is improved, but the ability to efficiently remove heat from all battery cells may be compromised
Solution Approach 1:
The integrated cell frame incorporates support ribs with different configurations at the top and bottom to optimize heat dissipation in different regions. The support ribs are designed with varying thicknesses, positions, or geometries to address local heat accumulation patterns while maintaining overall vertical symmetry in the frame structure.
Solution Approach 2:
The heat dissipation system utilizes three-dimensional routing through the integrated frame structure, allowing heat to be removed in multiple directions and planes. The support ribs create vertical and horizontal pathways for heat transfer, adding dimensional complexity to the thermal management while maintaining external vertical symmetry.
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 integrated cell frame design effectively prevents fire spread between battery cells by eliminating gaps and ensuring efficient heat dissipation, thereby reducing the risk of chain ignition.
Implementation Method 1
the firewall part may comprise a potting resin, in which it is injected into the cell insertion space and cured to be in a state of surrounding the respective battery cells
Data Source
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AI summary
A battery module related to one example of the present invention comprises a plurality of battery cells, a cell frame provided with a cell insertion space into which the respective battery cells are inserted, and a support rib dividing the cell insertion space and supporting the respective battery cells, and a firewall part provided in the cell insertion space and provided to surround the respective battery cells, wherein the cell frame is provided so that its thickness becomes thicker at least in part toward the central portion of the cell frame along the insertion direction of the battery cell.