Battery Module Heat Transfer Member for Gas Pocket Detection
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Solution Overview
Problem
Large-sized battery modules face challenges in heat dissipation and gas pocket detection, particularly under high current and rapid charging conditions, leading to potential overheating, reduced lifespan, and increased risk of explosion or ignition.
Innovation Solution
A battery module design incorporating a heat transfer member made of fluid material, such as a gel, that moves when a gas pocket occurs, and a pressure sensor to detect movement, enhancing heat dissipation and allowing for the diagnosis of abnormality in battery cells by filling spaces between the battery cell stack and bus bar frames, and contacting electrode leads and bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to obtain high output, then power and capacity are improved, but heat dissipation becomes difficult and temperature rises excessively
Solution Approach 1:
The patent introduces a gas pocket detection mechanism that operates in a different dimensional space (pressure/volume detection) to monitor battery cell abnormalities. This allows the system to detect gas pocket formation without interfering with the thermal management of the stacked battery cells, enabling continuous operation at high power while monitoring for thermal-related abnormalities.
Solution Approach 2:
The patent uses a gas pocket as an intermediary indicator to detect battery cell abnormalities. Instead of directly measuring temperature or heat generation in each cell, the system detects gas pocket formation which serves as a mediator indicating underlying thermal or chemical issues, allowing indirect monitoring of thermal problems in high-power battery stacks.
2Volume of moving object
If battery cells are placed in a narrow space to reduce size and weight, then integration is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent replaces direct thermal measurement mechanisms with a gas pocket detection system. Instead of using complex thermal sensors and cooling mechanisms in the limited space, the system uses pressure-sensitive detection of gas pocket formation to indirectly monitor thermal conditions, reducing the mechanical complexity and space required for thermal management.
Solution Approach 2:
The patent changes the monitoring parameter from direct temperature measurement to gas pocket volume/pressure detection. This parameter change allows the system to detect thermal-related abnormalities in compact battery modules without requiring extensive thermal management infrastructure, enabling efficient monitoring in space-constrained applications.
3Productivity
If rapid charging is implemented to meet high energy demands, then charging speed is improved, but gas pocket generation increases and becomes difficult to detect
Solution Approach 1:
The patent implements preliminary detection of gas pocket formation during rapid charging operations. By continuously monitoring for gas pockets before they become problematic, the system can detect early signs of abnormality caused by rapid charging, allowing preventive measures to be taken before serious issues develop.
Solution Approach 2:
The patent introduces a feedback mechanism through gas pocket detection that provides real-time information about battery cell conditions during rapid charging. This feedback loop allows the charging system to adjust operations based on detected gas pocket formation, enabling safe rapid charging by continuously monitoring and responding to cell status changes.
4Device complexity
If conventional unidirectional heat release path is used through thermal conductive resin layer, then structure is simple, but heat dissipation is insufficient under high current conditions
Solution Approach 1:
The patent makes the gas pocket detection system serve multiple functions: it detects gas pocket formation, indicates thermal abnormalities, and provides diagnostic information about battery cell health. This multi-functional approach allows the same detection mechanism to address both structural simplicity and improved thermal monitoring without adding separate complex heat dissipation systems.
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 addresses heat generation and gas pocket detection, improving insulation and stability, enabling efficient cooling and early detection of abnormalities, thus enhancing the safety and performance of battery modules.
Implementation Method 1
a heat transfer member formed between the battery cell stack and the end plates
Implementation Method 2
a movement sensing unit that senses movement of the heat transfer member
Data Source
AI summary
A battery module including a battery cell stack of a plurality of battery cells, a housing that surrounds the battery cell stack, a pair of end plates for covering the open front and rear surfaces of the battery cell stack, respectively, a heat transfer member formed between the battery cell stack and the respective end plate, and a movement sensing unit that senses movement of the heat transfer member.