Battery Module Dual-Case Sealing and Gas Venting
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Solution Overview
Problem
Battery module assemblies face issues with effective gas discharge, sealing reliability, and cooling efficiency, particularly in vehicle applications where pouch cells can rupture, leading to harmful gas entry and compromised assembly precision.
Innovation Solution
A battery module assembly design featuring a base substrate with stacked unit battery modules covered by a cell cover, a dual-case structure for enhanced sealing, and integrated gas discharge tubes, heat sink plates, and cooling fins to manage heat and gases effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece upper cover is used for the battery module, then the structure is simple, but sealing reliability deteriorates due to attachment of sensing members and assembly tolerance
Solution Approach 1:
The upper cover is divided into multiple separate covers (first upper cover and second upper cover) that are combined with the base substrate and with each other. This segmentation allows for improved sealing by creating multiple sealing interfaces and reducing the impact of assembly tolerance on overall sealing reliability, while still maintaining relatively simple individual cover structures.
2Reliability
If additional members are inserted to prevent sealing deterioration, then sealing reliability improves, but assembling precision is lowered due to assembly tolerance
Solution Approach 1:
The patent introduces positioning protrusions and positioning grooves that extend in vertical and horizontal dimensions to constrain the relative positions of the base substrate, first upper cover, and second upper cover. This multi-dimensional positioning approach improves assembling precision without requiring additional sealing members, thereby maintaining both sealing reliability and manufacturing precision.
3Quantity of substance
If pouch cells are used in the battery module, then energy density is high, but harmful gases can enter the vehicle when cells rupture due to impact or internal problems
Solution Approach 1:
The patent extracts and isolates the harmful gas risk by providing a dedicated gas discharge tube that vents gases away from the vehicle interior. The tube extends from the sealed battery module housing through the upper cover, creating a controlled extraction path for harmful gases to be discharged safely outside the vehicle, thereby protecting the vehicle interior while maintaining the high energy density benefits of pouch cells.
4Reliability
If the battery module is sealed to prevent gas entry, then safety improves, but cooling efficiency deteriorates due to lack of effective cooling methods
Solution Approach 1:
The patent introduces a cooling plate as an intermediary component that is coupled to the battery module housing. The cooling plate serves as a thermal mediator, conducting heat away from the battery cells through its contact surfaces while allowing the sealed housing to maintain its protective function. This intermediary cooling structure enables effective heat dissipation without compromising the sealing and safety of the battery module.
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 solution ensures effective sealing, reliable gas discharge, and improved cooling efficiency, enhancing the operational performance and safety of battery modules by preventing gas entry and maintaining assembly precision.
Implementation Method 1
integrated gas discharge tubes, heat sink plates, and cooling fins to manage heat and gases effectively
Implementation Method 2
heat sink plates, and cooling fins to manage heat and gases effectively
Implementation Method 3
integrated gas discharge tubes, heat sink plates, and cooling fins to manage heat and gases effectively
Data Source
AI summary
A battery module assembly, according to one embodiment of the present invention, comprises: a battery module including a base substrate and at least one battery cell, wherein a plurality of unit battery modules formed to surround a cell cover are stacked on the base substrate; and a battery case which is coupled to the base substrate, and which includes a first case surrounding the front surface of the battery module and a second case combined with the first case and surrounding a rear surface of the battery module. The present invention can effectively provide coupling reliability with an inner sensing membrane which is coupled to the battery module, and can seal the inside of the battery case by tightly combining the first case and the second case in a lateral direction.