Cylindrical Battery Module Foam Support for Impact 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 incorporating a module case, bus bar members, support plates, and foam members to stabilize cylindrical cells, using a dispenser unit for foam injection and guide holes for uniform distribution.

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 simple structure, but gaps are generated between cells causing instability and damage risk from external impacts

Engineering Contradiction:

Improveassembly simplicityVSAvoidcell stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a foam member (flexible material) to fill gaps between cylindrical battery cells. The foam member includes a base layer and protruding portions that fit into gaps between adjacent cells, providing flexible support and preventing cell movement while accommodating the cylindrical shape of the cells.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The foam member is pre-installed in the module case before placing the battery cells. The protruding portions of the foam member extend into the gaps between cells in advance, providing cushioning and positional support before the cells are subjected to external impacts during operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Adaptability or versatility

If gaps are left between cylindrical battery cells, then thermal expansion and installation are facilitated, but the battery cells become vulnerable to movement and damage from external impacts

Engineering Contradiction:

Improvethermal expansion accommodationVSAvoidimpact damage risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The foam member is made of flexible material that can accommodate thermal expansion of battery cells while maintaining contact support. The flexible nature allows the foam to deform with cell expansion/contraction while still preventing excessive movement that would lead to impact damage.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The foam member provides pre-installed cushioning in the gaps between cells, absorbing and distributing impact forces before they can cause damage to the battery cells during external shocks or vibrations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a rigid support structure is used to prevent cell movement, then cell stability is improved, but manufacturing complexity and difficulty of assembly increase

Engineering Contradiction:

Improvecell stabilityVSAvoidsupport structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex rigid support structures with a simple foam member that conformally fits into the module case. The foam member's flexibility allows it to provide stable support without requiring precise mechanical fixtures or complex assembly steps.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The foam member is designed to be self-positioning, where its protruding portions naturally fit into the gaps between cylindrical cells, providing automatic alignment and support without requiring complex positioning mechanisms or skilled assembly operations.

Inventive Principle:

Principle #25Self-service

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 cushioning:

Data Source

PatentUS20250329841A1Battery Module, and Battery Pack and Vehicle Including Battery Module

Publication Date: 2025.10.23 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.