Battery Module Busbar Inlay and Gas Permeable Membrane
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Solution Overview
Problem
Existing battery modules face challenges in mechanical stability, particularly at the top section, and safe gas discharge due to the conflict between mechanical protection and gas venting requirements, which can lead to damage and safety hazards during abnormal operations like thermal runaway.
Innovation Solution
The battery module design includes a cap assembly with a gas exhaust vent, busbars with inlays for enhanced mechanical support, and a top cover that seals the top section while allowing controlled gas discharge through a gas exhaust channel, ensuring both mechanical stability and safe venting of gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery module case is sealed and gas-tight to protect components from environmental impacts, then mechanical protection is improved, but gas accumulation during thermal runaway occurs leading to overpressure and explosion hazards
Solution Approach 1:
A gas permeable membrane is introduced as an intermediary component between the sealed case interior and exterior. The membrane allows gas molecules to pass through while maintaining the sealed structure, thus protecting components from environmental impacts while preventing gas accumulation and overpressure during thermal runaway events.
Solution Approach 2:
The gas permeable membrane utilizes porous material properties to achieve selective permeability. The porous structure allows gas molecules to diffuse through the membrane while maintaining structural integrity and sealing, enabling the case to remain mechanically protected yet breathable for gas discharge.
2Object-affected harmful factors
If venting openings are provided on battery cells to release gas during abnormal operations, then gas discharge is improved, but mechanical stability of the top section is compromised
Solution Approach 1:
The venting function is extracted from the individual battery cell level and relocated to the module level. Instead of providing venting openings on each cell that would compromise mechanical stability, the invention consolidates gas discharge functionality at the module level through the gas permeable membrane in the case, maintaining both mechanical stability and gas discharge capability.
Solution Approach 2:
The gas discharge mechanism is shifted from a localized cell-level feature to a module-level feature. The gas permeable membrane provides a distributed discharge path across the entire case surface, changing the dimensional approach from point-based venting to area-based permeability, thus maintaining mechanical integrity while enabling gas release.
3Strength
If the top section is sealed to protect electronics and terminals, then mechanical protection is improved, but controlled gas discharge path is lost
Solution Approach 1:
The gas permeable membrane provides self-service functionality by automatically allowing gas to pass through based on pressure differential without requiring active control mechanisms. The sealed top section maintains mechanical protection while the membrane autonomously enables gas discharge when internal pressure exceeds external pressure, eliminating the need for complex control systems.
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
This design improves the mechanical stability of the battery module by distributing mechanical loads evenly and provides a controlled path for gas discharge, reducing the risk of damage and safety hazards during abnormal operations.
Implementation Method 1
a gas permeable membrane is used to allow for a gas discharge from the battery module in a controlled manner
Data Source
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AI summary
The present invention is directed to a battery module (100) that comprises a plurality of aligned battery cells (10), wherein each of the battery cells (10) comprising an electrode assembly accommodated in a battery case (13), a cap assembly (14) placed on the battery case (13), a gas exhaust vent (99) in the cap assembly (14), and cell terminals (11, 12) protruding over the cap assembly (14). The battery module (100) further comprises a plurality of busbars (50,60,70) disposed on top of the cap assemblies (14), wherein each of the busbars (50,60,70) are configured for electrically connecting cell terminals (11, 12) of at least two battery cells (10) and the plurality of busbars (50,60,70) being configured for conducting the current of the battery module (100). Further, at least one inlay (40) is positively molded to at least one busbar (50,60,70) and having at most the height of the at least one busbar (50,60,70). A top cover (81) is disposed on top of the busbars (50,60,70) and covering the cap assemblies (14) of the battery cells (10), the busbars (50,60,70), and the at least one inlay (40), wherein the plurality of busbars (50,60,70) and the at least one inlay (40) form a support surface (43) for supporting the top cover (81) facing towards top cover (81).