Battery Holder with Hexagonal and Polygonal Cell Accommodations
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Solution Overview
Problem
In battery modules, abnormal heat generation in some cells can lead to heat conduction to adjacent normal cells, degrading them, and existing designs struggle to prevent this without increasing the size of the battery holder.
Innovation Solution
A battery module with a resin-based battery holder featuring hexagonal and polygonal accommodation portions arranged in a log pile pattern, reducing heat conduction between cells while maintaining efficient mounting, and utilizing a filler with endothermic properties to enhance heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the thermal capacity of the battery holder is increased to equalize cell temperatures, then temperature equalization is improved, but the size of the battery holder increases
Solution Approach 1:
The battery holder employs varying wall thicknesses in different regions to create local thermal capacity variations. The center region has greater thermal capacity than the outer regions, enabling effective temperature equalization of cells without uniformly increasing the entire holder's size. This localized approach addresses the temperature distribution problem while maintaining compact overall dimensions.
2Object-affected harmful factors
If the battery holder size is increased to prevent heat conduction between cells, then fire-spreading prevention is improved, but the mounting efficiency decreases
Solution Approach 1:
The battery holder is divided into multiple independent accommodation portions by partition walls. These partitions create separate compartments for individual cells, preventing heat conduction between adjacent cells. The segmented structure allows each cell to be independently isolated while maintaining a compact overall holder design that preserves mounting efficiency.
Solution Approach 2:
The partition walls between accommodation portions are designed with specific thicknesses and material properties to provide adequate thermal insulation. By concentrating insulation properties at the partition interfaces rather than throughout the entire holder, the design prevents heat conduction between cells while minimizing the overall increase in holder size and maintaining mounting efficiency.
3Object-affected harmful factors
If the filler content in the resin material is increased to enhance endothermic heat absorption, then fire-spreading prevention is improved, but the resin viscosity increases
Solution Approach 1:
The resin material's filler content is optimized within a specific range to balance endothermic heat absorption capability with processability. By carefully controlling the filler concentration parameter, the material achieves sufficient fire-spreading prevention through endothermic reaction while maintaining manageable viscosity for manufacturing processes such as injection molding.
Solution Approach 2:
The battery holder uses a composite resin material combining organic resin matrix with inorganic filler particles. This composite structure provides both the endothermic heat absorption properties needed for fire-spreading prevention and the structural integrity required for manufacturing. The composite formulation allows optimization of filler content to achieve the desired thermal properties without excessive viscosity increase.
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 heat transfer from abnormal cells to normal cells, preventing degradation and enhancing fire-spreading prevention while allowing for compact design and efficient temperature equalization.
Implementation Method 1
the lower limit of the content of the filler is determined on the basis of the endothermic amount
Data Source
AI summary
A battery module includes: cells; and a battery holder made of a resin material that contains a filler in a resin matrix. In the resin material of the battery holder, the lower limit of the content of the filler is determined on the basis of the endothermic amount, and the upper limit of the content of the filler is determined on the basis of the viscosity. Another battery module includes: cylindrical cells; and a battery holder having a plurality of tubular first accommodation portions each having a substantially hexagonal hole and a plurality of tubular second accommodation portions each having a substantially polygonal (heptagonal or more) hole. In the battery holder, the first accommodation portions and second accommodation portions are arranged in a manner of log pile by sandwiching a first column including the first accommodation portions between second columns including the second accommodation portions.