Battery Module Cell Barriers with Composite Flange Seals
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Solution Overview
Problem
High-output battery modules face challenges in efficiently managing heat exchange and stabilizing battery cells due to heat generation from repetitive charge and discharge cycles, which can lead to deterioration, ignition, or explosion, and require improved sealing and fixation mechanisms.
Innovation Solution
The implementation of cell barriers with flange portions made of different materials, including stainless steel, aluminum, or plastic, and elastic materials like rubber, which overlap lateral sides of battery cells to create sealing edges and define passageways for heat exchange mediums, enhancing thermal management and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cell barriers use single-material construction, then manufacturing is simple, but sealing performance and thermal management are insufficient
Solution Approach 1:
The cell barrier is constructed using composite materials: a rigid base part made of resin provides structural support, while elastic sealing rings made of different elastic materials provide sealing functionality. This composite structure resolves the contradiction by combining materials with different properties to achieve both structural integrity and sealing performance without excessive complexity.
Solution Approach 2:
Different portions of the cell barrier have different material properties tailored to their specific functions. The base part uses rigid resin for structural stability, while the sealing rings use elastic materials for sealing. This local differentiation of material quality allows each component to perform its function optimally, improving sealing performance without requiring the entire structure to be complex.
2Stability of the object's composition
If battery cells are tightly fixed, then positioning stability is improved, but heat dissipation may be compromised
Solution Approach 1:
The cell barrier is segmented into distinct functional zones: the base part for structural support and positioning, and separate sealing rings for thermal management and sealing. This segmentation allows the positioning function to be fulfilled by the rigid base while the sealing rings with flow passages handle heat dissipation, resolving the contradiction between tight fixation and heat dissipation.
Solution Approach 2:
The sealing rings act as intermediary elements between the rigid base part and the battery cells. They provide a compliant interface that maintains stable positioning while allowing thermal expansion and facilitating heat transfer through their elastic properties and integrated flow passages.
3Reliability
If sealing edges are made rigid, then structural strength is maintained, but sealing effectiveness decreases
Solution Approach 1:
The sealing edge is constructed as a composite of the rigid base part and elastic sealing rings. The rigid base provides structural strength while the elastic sealing rings provide sealing effectiveness through their deformability. This composite approach resolves the contradiction by combining materials with opposing properties in a single sealing edge structure.
Solution Approach 2:
The sealing edge exhibits different mechanical parameters at different locations: high rigidity in the base part for strength, and high elasticity in the sealing rings for sealing effectiveness. This spatial variation of material parameters allows the sealing edge to simultaneously satisfy both strength and sealing 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
This configuration improves heat exchange efficiency, stabilizes battery cell positioning, and extends the lifespan of the battery module by effectively managing heat and preventing potential issues like ignition or explosion.
Implementation Method 1
The first sealing edge and the second sealing edge may include an elastic member
Implementation Method 2
The cell barriers may define passageways along the battery cells for the flow of heat exchange medium between flow openings in the flanges
Data Source
AI summary
A battery module includes a plurality of battery cells and a plurality of cell barriers. Each cell barrier is between adjacent battery cells of the plurality of battery cells and includes at least one flange. The flange has a first flange portion and a second flange portion. The first flange portion has a first sealing edge extending therefrom and overlapping a first lateral side of one of the adjacent battery cells, and the second flange portion has a second sealing edge extending therefrom and overlapping a second lateral side of another of the adjacent battery cells.