Battery Module Adhesive Block Structure for Higher Energy Density
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Solution Overview
Problem
Existing battery modules have large overall weight and low space utilization, leading to reduced energy density due to bulky casings that occupy a significant space.
Innovation Solution
A battery module design featuring a casing with an opening filled by an adhesive block that covers the tab side of the cell stack, eliminating the need for additional end plates and plastic brackets, and incorporating a flexible printed circuit board connected via an elastic clamp to the cell tabs, enhancing thermal protection and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bulky casing is used to enclose the battery components, then the structural integrity and protection are improved, but the overall weight increases and space utilization decreases
Solution Approach 1:
The patent merges the protective casing function with the adhesive block by having the adhesive block serve dual purposes: bonding the cell stack to the casing and providing thermal protection. This eliminates the need for separate protective components, reducing overall weight while maintaining structural integrity.
Solution Approach 2:
The adhesive block is designed to perform multiple functions simultaneously: mechanical bonding, thermal insulation, and structural support. This multi-functionality allows the battery module to achieve reliable protection without adding extra components that would increase weight.
2Reliability
If a bulky casing is used to enclose the battery components, then the structural integrity and protection are improved, but the space utilization and energy density decrease
Solution Approach 1:
The protective function is merged into the adhesive block itself, which is already necessary for bonding components. This eliminates the need for additional protective casings or end plates, optimizing space utilization while maintaining structural integrity.
Solution Approach 2:
The patent extracts the protective function from a separate bulky casing and integrates it into the adhesive block. This extraction eliminates unnecessary components and reduces the overall volume occupied by protective structures.
3Reliability
If additional components like end plates and plastic brackets are used to block openings and protect tabs, then the protection and reliability are improved, but the part count increases and costs increase
Solution Approach 1:
The adhesive block is designed to simultaneously block the opening and protect the tab side, merging the functions of end plates and protective brackets into a single component. This reduces the part count while maintaining comprehensive protection.
Solution Approach 2:
The adhesive block serves as a multi-functional component that provides mechanical bonding, opening blocking, and tab protection. This universality eliminates the need for multiple specialized components, simplifying the overall structure.
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 design reduces weight, decreases part count, lowers costs, and increases energy density by simplifying the structure, improving thermal protection, and enhancing space utilization without additional components.
Implementation Method 1
Through the adhesive block, thermal protection is achieved, heat spread is prevented
Data Source
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AI summary
A battery module and a battery pack are provided. The battery module includes a casing (1) having an opening, a cell stack (2) having a tab side and mounted in the casing (1), and an adhesive block (3) filled at the opening to block the opening. A tab side of the cell stack (2) corresponds to the opening. The adhesive block (3) covers the tab side of the cell stack (2). An outer wall of the adhesive block (3) forms a portion of an outer wall of the battery module.