Battery Module Buffer Units for Impact Resistance

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Solution Overview

Problem

High power rechargeable batteries with non-aqueous electrolytes face issues of mechanical rigidity and swelling due to external impacts, leading to stability and performance deterioration, as the battery case can deform easily and the electrolyte decomposes during charge and discharge cycles.

Innovation Solution

A rechargeable battery module design incorporating a case with a first buffer unit and a cap assembly featuring second buffer units, which include depression portions on both inner and outer surfaces to absorb forces and prevent excessive swelling, enhancing mechanical stability and impact resistance without the need for additional elastic members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the battery case thickness is reduced to increase capacity, then the energy density is improved, but the mechanical rigidity deteriorates making the case easily deformed by external impact

Engineering Contradiction:

Improvebattery capacityVSAvoidmechanical rigidity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent incorporates buffer units with depression portions into the case structure before the battery is put into service. These pre-built cushioning structures are designed to absorb external impacts and prevent deformation of the thin-walled case, allowing the case to be made thinner while maintaining mechanical strength.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The buffer units utilize depression portions that create a porous or hollow structure within the case walls. This porous design allows the buffer units to compress under impact, absorbing energy while maintaining overall structural integrity, thus enabling thinner case walls without sacrificing strength.

Inventive Principle:

Principle #31Porous materials

2Quantity of substance

If the rechargeable battery utilizes non-aqueous electrolyte for high power, then the energy density is improved, but the electrolyte decomposes during charge and discharge cycles generating combustible gas causing swelling

Engineering Contradiction:

Improveenergy densityVSAvoidelectrolyte decomposition and swelling

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful swelling pressure generated by electrolyte decomposition into a beneficial cushioning effect. The buffer units with depression portions are designed to absorb this internal pressure, preventing case deformation while the electrolyte continues to function at high energy density.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The buffer units are pre-installed in the case structure to anticipate and absorb the swelling pressure that will be generated during battery operation. This beforehand cushioning prevents the case from deforming due to gas generation from electrolyte decomposition.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Stability of the object's composition

If additional elastic members are added to prevent case deformation, then the mechanical stability is improved, but the device complexity increases

Engineering Contradiction:

Improvemechanical stabilityVSAvoidstructural complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges the buffer units directly into the case structure itself, making the case walls themselves the cushioning elements. This integration eliminates the need for separate elastic members while maintaining mechanical stability, thus reducing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The case structure serves multiple functions: it contains the battery components, provides mechanical strength, and simultaneously acts as the buffer unit through its depression portions. This multi-functionality eliminates the need for additional dedicated cushioning components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 buffer units effectively reduce case expansion and improve cycle-life by absorbing external impacts, enhancing the module's stability and impact resistance while maintaining battery performance.

Implementation Method 1

a first buffer unit configured to reduce a force generated inside or outside the case on an inner surface and an outer surface of a bottom of the case

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS10333127B2Rechargeable battery module

Publication Date: 2019.06.25 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery module includes: a plurality of unit cells, wherein each of the unit cells comprises: an electrode assembly having a plate shape; a case receiving the electrode assembly and having an opening at one side; and a cap assembly sealing the opening of the case, wherein the case comprises a first buffer unit configured to reduce a force generated inside or outside the case on an inner surface and an outer surface of a bottom of the case, the cap assembly comprises a second buffer unit configured to reduce a force generated inside or outside the case on an inner surface and an outer surface of the cap assembly, and the first buffer unit of each unit cell partially overlaps the first buffer unit of a neighboring unit cell.