Pouch Battery Module Foam Spacing for Uniform Cell Pressure
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Solution Overview
Problem
Current battery modules face reduced cycle life and durability due to uneven surface pressure distribution among pouch-type battery cells, leading to rapid degradation and shortened lifespan when exposed to high temperatures and external impacts.
Innovation Solution
Incorporating a foam member between the cell frame and battery cells, along with a guide member such as guide pins, strings, insulating films, or mesh sheets to maintain consistent spacing and reduce pressure deviations, thereby stabilizing the arrangement and pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If compression pads are located between pouch-type battery cells to hold and move the cell assembly, then the battery cells are secured in position, but the force applied to hold and move the cell assembly is different for each battery cell due to deviation in pressing force, causing uneven arrangement and difference in compression amount
Solution Approach 1:
The patent introduces a foam member as an intermediary between the compression pads and the battery cells. This foam member distributes the pressing force uniformly across all battery cells, preventing the deviation in force that occurs with direct compression pad contact. The foam member acts as a mediator that transforms the concentrated force from compression pads into distributed uniform pressure, thereby achieving both secure positioning and precise arrangement of battery cells.
Solution Approach 2:
The patent changes the physical state and properties of the compression system by introducing a deformable foam member. The foam member deforms under compression to adapt to the exact dimensions and positions of the battery cells, changing from a rigid compression pad system to a flexible, adaptive system. This parameter change allows the system to accommodate variations in cell positioning while maintaining uniform pressure distribution.
2Ease of manufacture
If initial thicknesses of compression pads are constant but intervals between battery cells are not constant, then the compression pads can be manufactured with consistent dimensions, but degrees to which the compression pads are compressed are different, increasing deviation of surface pressure applied to battery cells
Solution Approach 1:
The patent changes the physical state of the compression element from a rigid solid (compression pad) to a deformable foam material. This parameter change allows the compression element to adapt its shape and thickness during compression, transforming the inconsistent compression into uniform pressure distribution. The foam member's ability to deform and conform to the actual spacing between cells eliminates the surface pressure deviation problem while maintaining ease of manufacture.
Solution Approach 2:
The patent uses foam material with specific cellular structure and mechanical properties that combine the ease of manufacturing with the ability to distribute pressure uniformly. The foam's composite structure allows it to be manufactured with consistent initial properties while exhibiting variable compression characteristics that adapt to different cell intervals, thereby achieving both manufacturing ease and pressure uniformity.
3Stability of the object's composition
If compression pads are used to hold battery cells, then the battery cells are secured, but when battery cells swell due to gas generation in high temperature environments, degradation occurs and surface pressure deviation is further increased, rapidly degrading performance and shortening lifespan
Solution Approach 1:
The foam member serves as a protective intermediary between the compression system and the battery cells. When cells swell due to gas generation, the foam member absorbs the expansion forces through its deformable structure, preventing direct transmission of excessive stress to the cells. This intermediary role protects the cells from degradation while maintaining the securing function, thereby improving reliability and extending cycle life.
Solution Approach 2:
The foam member provides beforehand cushioning by being pre-installed between the compression pads and the battery cells. This cushioning layer is in place before any swelling occurs, ready to absorb and distribute the forces when gas generation and cell expansion happen. The prior cushioning prevents the harmful concentration of stress that would otherwise occur during thermal expansion and gas generation, protecting the cells from degradation.
4Quantity of substance
If a plurality of pouch-type battery cells are accommodated in a cell frame with compression pads, then the battery module achieves high capacity configuration, but surface pressure is concentrated only on some battery cells, causing rapid degradation and shortened lifespan
Solution Approach 1:
The foam member acts as a universal intermediary across all battery cells in the high-capacity module configuration. It ensures that the pressing force from the compression pads is distributed evenly to every cell regardless of position, preventing the concentration of surface pressure on specific cells. This uniform pressure distribution maintains the high capacity configuration while preventing the rapid degradation that would otherwise occur, thereby extending the lifespan of all cells in the 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 effectively reduces collisions and degradation, extends the lifespan of battery cells by maintaining consistent surface pressure and guiding regular cell spacing, enhancing manufacturing efficiency and reducing weight and swelling-induced pressure increases.
Implementation Method 1
a foam member filled in at least one of between the cell frame and the plurality of battery cells and between the plurality of battery cells
Data Source
AI summary
A battery module includes a plurality of battery cells arranged in at least one direction and spaced apart from one another by a certain interval, a cell frame including a receiving space in which the plurality of battery cells are accommodated, and a foam member filled in at least one of between the cell frame and the plurality of battery cells and between the plurality of battery cells.