Battery Module Escape Area and Elastic Housing for Crash Safety

Solution Overview

Problem

Electric vehicle battery modules face safety risks due to the high energy density of battery cells, which can lead to fires and explosions in the event of a crash, and existing steel housings are heavy, expensive, and insufficiently protective.

Innovation Solution

Incorporating an escape area within the battery module housing to allow battery cells to move and reduce force absorption, combined with an elastic battery module housing to absorb crash forces and prevent severe damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery cells are densely packed to increase energy storage capacity, then the total capacity and driving performance are improved, but the risk of flame propagation and chain reactions increases

Engineering Contradiction:

Improvebattery cell capacityVSAvoidflame propagation risk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The battery module housing is divided into multiple receptacles that separate individual battery cells. Each receptacle acts as an independent compartment that physically isolates battery cells from each other, preventing flame propagation between adjacent cells while maintaining high density packing within each receptacle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery module housing serves as an intermediary structure between battery cells and the external environment. It includes flame-retardant materials and thermal insulation layers that mediate heat and flame transfer, preventing direct propagation while allowing efficient heat dissipation under normal operating conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If thick sheet steel is used for battery module housing to protect battery cells from crash damage, then the protective capability is improved, but the weight and cost increase

Engineering Contradiction:

Improvecrash protection capabilityVSAvoidbattery module weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The battery module housing uses composite materials consisting of a thin steel substrate combined with polymer coatings and foam insulation layers. This composite structure provides enhanced protective capability through the synergistic effects of different materials: the steel substrate provides structural strength, while the polymer and foam layers provide energy absorption and additional protection, reducing the need for thick steel and thereby reducing weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing incorporates foam insulation and polymer layers that act as cushioning elements before crash forces reach the battery cells. These materials are designed to deform and absorb impact energy during crash events, providing beforehand cushioning that protects the battery cells from direct impact forces while using less steel than traditional designs.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Weight of moving object

If thin steel housing is used to reduce weight, then the weight and cost are reduced, but the protective capability becomes insufficient

Engineering Contradiction:

Improvebattery module weightVSAvoidcrash protection capability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The housing uses composite materials consisting of a thin steel substrate combined with polymer coatings and foam insulation layers. This composite structure provides enhanced protective capability through the synergistic effects of different materials: the steel substrate provides structural strength, while the polymer and foam layers provide energy absorption and additional protection, reducing the need for thick steel and thereby reducing weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing incorporates foam insulation and polymer layers that act as cushioning elements before crash forces reach the battery cells. These materials are designed to deform and absorb impact energy during crash events, providing beforehand cushioning that protects the battery cells from direct impact forces while using less steel than traditional designs.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Stability of the object's composition

If rigid housing is used to maintain structural integrity, then the structural stability is improved, but the ability to absorb crash forces through deformation is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidcrash force absorption

Core Design Contradiction:

Stability of the object's compositionVSForce

Solution Approach 1:

The housing parameters are optimized to balance rigidity and deformability: the steel substrate thickness and geometry are designed to maintain structural integrity and prevent collapse, while the polymer and foam layers are designed with specific density and thickness parameters that allow controlled deformation for energy absorption. This parameter optimization enables the housing to simultaneously maintain structural integrity and absorb crash forces.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The housing uses composite materials consisting of a thin steel substrate combined with polymer coatings and foam insulation layers. This composite structure provides enhanced protective capability through the synergistic effects of different materials: the steel substrate provides structural strength, while the polymer and foam layers provide energy absorption and additional protection, reducing the need for thick steel and thereby reducing weight.

Inventive Principle:

Principle #40Composite materials

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 reduces the risk of battery cell damage and enhances safety by allowing cells to escape force and utilizing an elastic housing for better crash absorption, while also reducing weight and cost compared to traditional steel enclosures.

Implementation Method 1

an elastic battery module housing to absorb crash forces and prevent severe damage

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentEP3053207B1Battery module with extra area, battery pack and electric vehicle

Publication Date: 2019.06.12 COVESTRO DEUTSCHLAND AG

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Figure 3~4

AI summary

The invention relates to a battery module (8a-f, 30, 56a-c) having a battery module housing (10a, 32), wherein the battery module housing (10a, 32) encloses a battery module interior space (12a), wherein the battery module housing (10a, 32) has, in the battery module interior space, receptacles (34a-b) for a prespecified number of battery cells (14, 36a-b), and wherein the battery module (8a-f, 30, 56a-c) has an escape region (16) in the battery module interior space (12a) in addition to the receptacles (34a-b), said escape region being dimensioned and arranged such that at least one battery cell (14, 36a-b) which is received in a receptacle can be displaced at least partially into the escape region (16). The invention further relates to a battery pack (2, 50) having a battery pack housing (4, 52), wherein the battery pack housing (4, 52) encloses a battery pack interior space (6, 54), wherein the battery pack housing (4, 52) has, in the battery pack interior space, at least one receptacle for a battery module (8a-f, 30, 56a-c), and wherein the battery pack (2, 50) has a battery module (8a-f, 30, 56a-c) according to the invention which is received in the receptacle. Finally, the invention further relates to an electric vehicle comprising a battery module (8a-f, 30, 56a-c) of this kind and/or a battery pack (2, 50) of this kind.