Battery Module Flat Plate Gas Venting and Thermal Design
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Solution Overview
Problem
Existing battery modules with multiple cells connected in series and parallel configurations result in large sizes, compromising energy density and safety when space constraints are a priority, and the integration of exhaust ducts further reduces volumetric energy density.
Innovation Solution
A battery module design where each battery block has cells with aligned openings for gas release, accommodated in holders with flush flat plates above, allowing gas to pass through and connecting adjacent blocks' exhaust passages without gaps, ensuring safety and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cells are inserted in holders with cylindrical holes to hold and cool the cells, then the cells are securely accommodated and cooled, but the total size of the battery pack becomes large
Solution Approach 1:
The holder and flat plate are merged into a single integrated component. The flat plate serves dual functions: it forms the holder structure with cylindrical holes for cell accommodation and cooling, while also extending to cover gaps between adjacent battery packs. This integration eliminates the need for separate gap-covering components, reducing overall volume while maintaining cell holding and cooling functions.
Solution Approach 2:
The flat plate is designed to perform multiple functions simultaneously: (1) forming holder structures to accommodate and cool cells, (2) covering gaps between adjacent battery packs to prevent gas passage, and (3) providing structural support. This multi-functionality reduces the number of separate components needed, thereby reducing the total battery pack size while maintaining reliability.
2Volume of stationary object
If the number of cells is reduced to decrease battery pack size, then the total size is reduced, but the volume ratio of cells to battery pack decreases, reducing energy density
Solution Approach 1:
By merging the holder and flat plate into a single component, the structural overhead is reduced. This allows for more efficient space utilization within the battery pack, enabling a higher proportion of the volume to be occupied by active cell material, thereby improving energy density even when the total number of cells is reduced for size constraints.
3Quantity of substance
If members other than cells are omitted to increase energy density, then volumetric energy density improves, but safety issues arise
Solution Approach 1:
The integrated flat plate structure combines safety functions (gap covering to prevent gas passage between battery packs) with structural support functions. This eliminates the need for separate safety components, allowing safety features to be incorporated without adding extra members that would reduce volumetric energy density.
Solution Approach 2:
The flat plate performs multiple safety-related functions: it covers gaps between adjacent battery packs to prevent gas passage, provides structural support to maintain pack integrity, and works with the holder to ensure proper cell accommodation. This multi-functionality ensures safety requirements are met without requiring additional dedicated safety components that would reduce energy density.
4Volume of stationary object
If exhaust ducts are integrated into the battery pack structure, then the battery pack is more compact, but the passage for connecting exhaust ducts reduces volumetric energy density
Solution Approach 1:
The exhaust duct function is merged with the flat plate structure. The flat plate extends to cover gaps and can be designed to incorporate exhaust passage routes. This integration allows exhaust functionality to be achieved without requiring separate dedicated exhaust duct components that would occupy additional volume and reduce energy density.
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 achieves a high degree of safety and energy density by protecting the space between holders with electrode plates, preventing gas from entering gaps and maintaining efficient energy storage.
Implementation Method 1
A battery module includes a plurality of battery blocks which are connected to each other and each of which includes a plurality of cells... a flat plate in touch with the cells is disposed such that the gas passes above the flat plate
Data Source
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AI summary
A battery module includes: battery blocks which are connected to each other and each of which includes cells. Each of the cells has an opening through which a gas generated in the cell is released to an outside. Each of the battery blocks has a holder in which the cells are accommodated with the openings of the cells being aligned on a same side. On a side of the battery block on which the openings are aligned, a flat plate in touch with one end of the cells is disposed such that the gas passes above the flat plate. Each adjacent two of the battery blocks are disposed such that the flat plates are substantially flush with each other. The flat plate of one of the each adjacent two of the battery blocks extends above the holder of the other of the each adjacent two of the battery blocks.