Battery Module Double-Layer Housing for Fire and Condensation Isolation
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Solution Overview
Problem
Battery modules face issues of fire propagation and electrical short circuits due to ignition or explosion of secondary batteries, which can lead to larger fires and secondary explosions, and dew condensation can create current paths causing electric leaks and short circuits.
Innovation Solution
A battery module design featuring a module case with insulating plates and cover portions that form a double layer to prevent fire propagation and a duct system with insulating plates to manage dew condensation, along with sealing members to contain fire and insulate electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery module uses a conventional housing structure without additional protective layers, then the device complexity is reduced, but fire can propagate and melt the housing, creating holes that lead to larger fires and secondary explosions
Solution Approach 1:
The patent implements a nested protective structure where an inner protective layer is placed inside the housing and an outer protective layer is placed outside the housing. This nested arrangement provides multiple barriers against fire propagation while maintaining a relatively compact overall structure, thereby improving fire safety without excessively increasing device complexity.
Solution Approach 2:
The patent employs composite protective layers with different material properties - the inner protective layer uses materials resistant to melting and fire propagation, while the outer protective layer provides additional fire resistance and structural support. This composite material approach enhances fire safety by combining the advantages of different materials in a multi-layer configuration.
2Strength
If the housing structure is made of iron to provide structural strength, then the strength is improved, but high current can flow through the housing during fire, causing gas insulation breakdown and secondary explosions
Solution Approach 1:
The patent introduces insulating plates as intermediary elements positioned between conductive components and the iron housing. These insulating plates act as mediators that prevent direct electrical contact through the housing, blocking high current flow paths while allowing the iron housing to maintain its structural strength. This resolves the contradiction by decoupling the structural function from the electrical conduction risk.
3Reliability
If the battery module uses a simple single-layer protective design, then the device complexity is reduced, but dew condensation can create current paths causing electric leaks and short circuits
Solution Approach 1:
The patent uses a nested multi-layer protective structure where inner and outer protective layers are positioned at different locations within the housing. This nested arrangement creates multiple barriers against dew condensation, preventing it from reaching electrical components and forming conductive paths, thereby improving electrical insulation reliability.
Solution Approach 2:
The patent applies protective layers with specific local properties - the inner protective layer is positioned to protect against dew condensation forming on internal surfaces, while the outer protective layer provides additional insulation. This localized quality approach addresses the dew condensation issue at specific critical locations without requiring complete coverage, balancing protection with complexity.
Data Source
AI summary
A battery module prevents a fire from increasing in size and prevents electrical short circuits due to dew condensation in case of a fire. A battery module for achieving the object as described above includes a cell assembly having a plurality of battery cells, a front cover including an upper wall, a lower wall, a left wall, and a right wall, which form an inner space, and a module case accommodating the cell assembly in the inner space, coupled to the front cover, and provided with a cover portion that has a portion protruding to face at least one of the upper wall, the lower wall, the left wall, and the right wall.