Battery Module Gas Duct Member for Leakage Prevention

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Solution Overview

Problem

Conventional battery packs with safety valves for gas release are costly due to the need for outlet coupling parts and T-shaped joints, which can also cause gas leakage.

Innovation Solution

A battery module design featuring a gas duct member that covers all safety valves and a seal member for hermetic sealing between the gas duct and cell cases, eliminating the need for connection nozzles and joints, thereby reducing production costs and preventing gas leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If outlet coupling parts and T-shaped joints are used for gas discharge connection, then gas can be discharged from safety valves, but production costs increase and gas leakage risk arises

Engineering Contradiction:
Improvegas discharge reliabilityVSAvoidconnection structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the gas discharge functions of multiple safety valves into a single integrated gas discharge line. Instead of connecting each safety valve separately to the external environment using multiple coupling parts and joints, the invention creates a common gas discharge pathway that collects gas from all safety valves and discharges it through a single outlet, thereby reducing the number of connection components and eliminating potential leakage points.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The gas discharge line serves multiple functions: it collects gas from multiple safety valves, provides a common discharge pathway, and connects to the external environment through a single interface. This multi-functional design replaces what would otherwise require multiple separate connection systems, reducing both complexity and cost while maintaining reliable gas discharge capability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If outlet coupling parts and T-shaped joints are used for gas discharge connection, then gas discharge function is achieved, but production costs increase

Engineering Contradiction:
Improvegas discharge functionVSAvoidproduction cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The invention combines multiple separate gas discharge connections into a single integrated system. By merging the discharge pathways of multiple safety valves into one common line, the number of required coupling parts and joints is dramatically reduced, leading to lower production costs for materials, assembly, and quality inspection while maintaining the essential gas discharge function.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates unnecessary intermediate connection components (outlet coupling parts and T-shaped joints) from the gas discharge system. By directly integrating the safety valve outlets into a common discharge line, the design removes extraneous parts that increase production cost without adding functional value, achieving cost reduction while preserving gas discharge reliability.

Inventive Principle:
Principle #2Taking out (Extraction)

3Reliability

If connection nozzles and joints are used for gas discharge, then safety valves can release gas, but gas leakage is likely to occur

Engineering Contradiction:
Improvegas release capabilityVSAvoidgas leakage
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple separate gas discharge connections into a single integrated gas discharge line. This consolidation reduces the total number of connection interfaces where gas leakage could occur. By collecting gas from multiple safety valves through a common pathway and discharging it through one outlet, the system minimizes the number of potential leakage points while maintaining the essential gas release capability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The invention converts the potential harm of multiple leakage-prone connection points into a benefit by creating a single, simplified discharge pathway. The design recognizes that fewer connections mean fewer leakage risks, and transforms the complex multi-connection system into a streamlined single-line system that is inherently more reliable against gas leakage while preserving the safety function.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 provides a cost-effective and reliable battery module with enhanced sealing capabilities, preventing gas and electrolyte leakage while maintaining efficient cooling and electrical insulation.

Implementation Method 1

a seal member for hermetically sealing between at least each cell case and the gas duct member

Methodology Applied
Scientific EffectHermetic sealing:

Implementation Method 2

a gas duct member which covers all the safety valves of the plurality of cells included in the battery module, thereby forming a gas discharge path between the gas duct member and the safety-valve mounting walls

Methodology Applied
Scientific EffectGas flow through duct:

Data Source

PatentUS7875375B2Battery module, battery pack, and method for producing the battery module
Publication Date: 2011.01.25 TOYOTA JIDOSHA KK
  • US7875375B2 patent drawing
  • US7875375B2 patent drawing
  • US7875375B2 patent drawing

AI summary

An inexpensive battery pack including a battery module wherein a safety valve is provided for each cell in which battery pack gas leakage can be prevented. A battery pack 100 has a plurality of battery modules 110 each including a plurality of cells 120 respectively provided with a safety valve 123. The plurality of cells 120 included in each battery module 110 are arranged such that safety-valve mounting walls 121a are oriented in the same direction. Each battery module 110 comprises a gas duct member 130 covering all the safety valves 123 of the cells 120 included therein and forming a gas discharge path 131 between the gas duct member 130 and the safety-valve mounting walls 121a, and a sealing member 160 for hermetically sealing the gaps between each cell case 121 and the gas duct member 130.