Cylindrical Battery Module Foam Filling for Cell Stability

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Solution Overview

Problem

Conventional battery modules face instability and damage risks due to gaps between cylindrical cells, leading to potential damage from external impacts.

Innovation Solution

A battery module design featuring a module case with a support plate and foam member, bus bar members, and filling guide insert holes to stabilize and secure battery cells, using a dispenser unit for efficient foam filling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cylindrical battery cells are stacked to form a battery module, then the battery module can be assembled with standard cylindrical cells, but gaps are generated between the cells which leads to instability and potential damage from external impacts

Engineering Contradiction:

Improveease of manufactureVSAvoidstability of battery cells

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a foam member (flexible material) to fill the gaps between cylindrical battery cells. The foam member conformally fills the irregular spaces between cells, providing stable support and preventing cell movement while accommodating the cylindrical shape of the cells. This resolves the contradiction by maintaining ease of manufacture with cylindrical cells while eliminating the instability caused by gaps.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If a foam member is filled in the space between battery cells to prevent movement, then stability and safety are improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvestability of battery cellsVSAvoidcomplexity of battery module structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the foam member into multiple segments or pieces that are separately positioned between the battery cells. Each foam segment fills the gap between adjacent cells independently. This segmentation approach provides stable support to prevent cell movement while simplifying the manufacturing process, as the foam pieces can be easily inserted without requiring complex molding or filling operations. The segmented approach reduces device complexity compared to a single-piece foam structure.

Inventive Principle:

Principle #1Segmentation

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

Enhances stability and safety by preventing cell movement and damage from external impacts, improving manufacturing efficiency and safety of battery packs and vehicles.

Implementation Method 1

a foam member filled in a space between the plurality of battery cells at a bottom portion of the support plate

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20250337074A1Battery Module, and Battery Pack and Vehicle Including Battery Module

Publication Date: 2025.10.30 LG ENERGY SOLUTION LTD

AI summary

Disclosed is a battery module, which includes a module case having a predetermined accommodation space; a plurality of battery cells accommodated in the module case; a plurality of bus bar members provided at an upper side of the plurality of battery cells to electrically connect the plurality of battery cells; a support plate disposed between the plurality of battery cells and the plurality of bus bar members to support the plurality of bus bar members; and a foam member filled in a space between the plurality of battery cells at a bottom portion of the support plate.