Battery Module Heat Insulator With Recessed Buffer for Expansion Force
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Solution Overview
Problem
Existing battery modules require large-scale restraining members to manage the increased reaction force from battery expansion, leading to increased size and weight.
Innovation Solution
A heat insulator comprising a heat insulating sheet with a recessed portion and a buffer sheet bonded to it, where the buffer sheet is more easily deformable, allowing the buffer sheet to enter the recessed portion during expansion, reducing the reaction force and enabling a smaller, lighter battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a buffer sheet is used to allow compressive deformation during battery expansion, then the heat insulator can follow battery expansion, but distortions accumulate in the buffer portion and reaction force increases
Solution Approach 1:
The buffer sheet is designed with a porous structure that allows it to compress and deform during battery expansion. The porous structure enables the buffer sheet to absorb compression forces through cell collapse and material deformation, reducing the accumulation of distortions and the resulting reaction force on the battery.
Solution Approach 2:
The heat insulator is designed with heterogeneous structure where the buffer sheet portion has different material properties (more easily compressively deformed) compared to the heat insulating sheet portion. This local differentiation allows the buffer sheet to specifically handle compression forces while the heat insulating sheet maintains thermal insulation performance.
2Reliability
If a large-scale restraining member is used to cope with the reaction force, then the battery expansion can be controlled, but the size and weight of the battery module increase
Solution Approach 1:
The restraining function is extracted from a separate large-scale restraining member and integrated into the buffer sheet itself. The buffer sheet's porous structure and compressible material properties enable it to provide the necessary restraining force during battery expansion, eliminating the need for additional heavy restraining components.
Solution Approach 2:
The material parameters of the buffer sheet are specifically selected to achieve optimal balance between compressibility and restraining force. By adjusting the density, cell structure, and material composition of the buffer sheet, the system achieves effective battery expansion control with minimal reaction force, reducing the overall size and weight requirements.
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 reduces the need for a strong restraining member, minimizing the size and mass of the battery module while effectively managing thermal expansion.
Implementation Method 1
the buffer sheet is formed of a material that can be more easily compressively deformed than the heat insulating sheet
Implementation Method 2
when the battery cells expand and the heat insulator is compressively deformed, the buffer sheet is deformed such that a portion of the buffer sheet enters the recessed portion, so that a distortion that is accumulated in the buffer sheet is released
Implementation Method 3
a heat insulating sheet, and a buffer sheet bonded to the heat insulating sheet
Data Source
Figure 1
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AI summary
A battery module includes battery cells each of which includes a pair of broad width surfaces and that are arranged such that the broad width surfaces are opposed to each other and a heat insulator arranged between an adjacent pair of battery cells. The heat insulator includes a heat insulating sheet and a buffer sheet bonded to the heat insulating sheet. The heat insulating sheet is formed of a material that can be more easily compressively deformed than the heat insulating sheet. The heat insulating sheet includes a recessed portion in a surface to which the buffer sheet is bonded.