Battery Module Cell Restraint Using Curable Epoxy Filler
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Solution Overview
Problem
Lithium ion battery cells in battery modules tend to swell during use, leading to resistance growth and reduced lifespan, which complicates manufacturing and thermal management, and requires improved mechanisms for restraint and thermal conductivity.
Innovation Solution
A battery module design using a curable epoxy resin filler material between lithium ion battery cells and heat exchanger fins, which mechanically restrains the cells and serves as a thermal conduction path, preventing swelling and enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium ion battery cells are tightly packed within the battery module packaging to maximize energy density, then energy density is improved, but cell swelling causes resistance growth and reduced lifespan
Solution Approach 1:
A restraining medium is introduced as an intermediary substance between the battery cells and the module packaging. This medium mechanically restrains the cells to prevent swelling while maintaining close proximity for high energy density. The restraining medium serves as a mediator that resolves the conflict between tight packing and cell volume stability.
Solution Approach 2:
The restraining medium undergoes a parameter change from liquid to solid through curing. In the liquid state, it flows to fill gaps and provide thermal contact; in the solid state, it provides mechanical restraint. This phase transition enables the system to achieve both high energy density and cell stability.
2Reliability
If a restraining medium is used to prevent cell swelling, then battery lifespan is improved, but thermal management capability must be enhanced
Solution Approach 1:
The restraining medium utilizes a parameter change from liquid to solid through curing. In the liquid state, it provides excellent thermal contact and fills all gaps between cells and heat exchangers. After curing to solid, it maintains mechanical restraint while preserving thermal pathways. This sequential application of different physical states resolves both thermal management and mechanical restraint requirements.
Solution Approach 2:
The restraining medium is described as a curable composition that combines thermal conductivity and mechanical restraint properties. This composite material approach integrates multiple functions (thermal management and structural support) into a single substance, eliminating the need for separate thermal interface materials and restraining structures.
3Stability of the object's composition
If traditional mechanical restraint mechanisms are used to hold battery cells, then cell stability is improved, but manufacturing complexity and thermal management are complicated
Solution Approach 1:
The patent merges multiple functions into a single restraining medium: mechanical restraint, thermal management, and electrical insulation. Instead of using separate components for each function (clamps or frames for restraint, separate thermal paste for heat transfer, and insulation barriers), the curable composition performs all these functions simultaneously, greatly simplifying the manufacturing process and component count.
Solution Approach 2:
The restraining medium is applied in a liquid state that allows it to self-flow and self-position around the battery cells and heat exchangers. During curing, it self-hardens to provide mechanical restraint without requiring external clamping mechanisms or complex assembly steps. This self-service capability eliminates the need for additional restraint components and simplifies manufacturing.
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 effectively prevents cell swelling, improves thermal management, and extends the lifespan of battery modules by maintaining energy density and performance, while providing electrical insulation and thermal conductivity.
Implementation Method 1
a temperature sensing component is coupled to the fin separating the first and second lithium ion battery cells. A filler material formed from a curable epoxy resin is disposed within the battery module housing and between the first and second lithium ion battery cells and the fin, such that the filler material is configured to cure to mechanically restrain the first and second lithium ion battery cells within the battery module housing and to conduct thermal energy between the first and second lithium ion battery cells and the fin
Implementation Method 2
The filler material covers a free end of the fin and the temperature sensing component, and the temperature sensing component is coupled to a conductor extending out of the filler material
Data Source
AI summary
A battery module includes a battery module housing, a heat exchanger including a plurality of fins disposed in the housing, a first lithium ion battery cell and a second lithium ion battery cell disposed within the battery module housing. The first lithium ion battery cell and the second lithium ion battery cell are separated by a fin of the plurality of fins. The module includes a temperature sensing component coupled to the fin separating the first and second battery cells. Filler material is disposed within the housing and between the battery cells and the fins to mechanically restrain the battery cells within the battery module housing. The filler materials conduct thermal energy between the battery cells and the fin. The filler material covers a free end of the fin and the temperature sensing component. The temperature sensing component is coupled to a conductor extending out of the filler material.