Battery Module Insulating Molding Part for Moisture Protection
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Solution Overview
Problem
Battery modules used in electric vehicles and power storage devices are prone to malfunction and reduced lifespan due to moisture ingress, leading to corrosion and short circuits in humid environments, which increases defect rates and compromises safety.
Innovation Solution
A battery module design featuring an insulative molding part that covers the conductive connection points between the printed circuit board (PCB) and battery cells, preventing moisture penetration and reducing the risk of short circuits, while using a stacked battery cell assembly with cartridges and fastening members for structural stability and easy extension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery cells are arranged in tight contact to form a compact battery module, then space utilization is improved, but moisture can easily penetrate into electrical connection regions causing short circuits
Solution Approach 1:
The battery module is segmented into distinct functional regions: a stacking region where battery cells are tightly arranged for space efficiency, and a separate electrical connection region where the PCB is positioned. This spatial segmentation prevents moisture penetration pathways from reaching electrical connections while maintaining compact cell arrangement.
Solution Approach 2:
The cover member acts as an intermediary structure between the battery cells and the PCB. It provides a protective barrier that isolates the electrical connection region from the battery cell assembly, preventing moisture ingress to the PCB while allowing electrical connections to be established through the cover member's through-holes.
2Area of stationary object
If circuits are disposed in a dense state on the PCB to reduce battery pack size, then space efficiency is improved, but the PCB becomes more susceptible to corrosion from moisture
Solution Approach 1:
The cover member functions as a protective shell that encloses the PCB and its dense circuit patterns. This shell structure prevents moisture from reaching the PCB surface, thereby protecting the densely packed circuits from corrosion while maintaining the compact PCB design.
Solution Approach 2:
The cover member creates a protected environment around the PCB, isolating it from the external humid environment. This effectively establishes an inert barrier that prevents harmful moisture interaction with the PCB circuits.
3Adaptability or versatility
If the battery module structure is made extendable to increase capacity, then adaptability is improved, but the risk of moisture ingress and short circuits increases
Solution Approach 1:
The battery module employs a modular segmented structure where battery cells are arranged in stacks that can be easily extended by adding or removing cell stacks. The cover member and PCB assembly serve as reusable modular units that maintain the same protective configuration regardless of the number of battery cell stacks, ensuring consistent moisture protection during extension.
Data Source
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AI summary
Disclosed herein is a battery module including a battery cell assembly constituted by at least two battery cells arranged such that the battery cells are in tight contact with each other or the battery cells are adjacent to each other, a front plate and a rear plate fixed to the battery cell assembly such that the front plate and the rear plate cover outermost ones of the battery cells, an electrically insulative cover member mounted at an upper end of the battery cell assembly, the electrically insulative cover member being provided with through holes, through which electrode terminals of the battery cells extend, a printed circuit board (PCB) mounted on a bottom of the cover member, a plurality of conductive connection parts arranged on the cover member in a state in which the conductive connection parts are mounted at the cover member, the conductive connection parts being connected to the electrode terminals of the battery cells and the PCB to provide electrical connection between the battery cells and the PCB, and an lower molding part located on the PCB at the bottom of the cover member, the lower molding part covering the connection between the PCB and the conductive connection parts.