Battery Module Insulation Member with Shock-Absorbing Ribs
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Solution Overview
Problem
Lithium secondary battery packs, especially large-sized ones, face safety issues due to low insulativity and vulnerability to external forces, leading to potential fires or explosions from abnormal operations and swelling of battery cells, which conventional safety systems fail to adequately address.
Innovation Solution
A battery pack design featuring a battery module array with an insulation member made of insulative foam between the module array and end plates, equipped with ribs to absorb external shocks and define a coolant flow channel, enhancing insulativity and durability while allowing for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional safety systems (protection circuit, PTC element, safety vent) are used in lithium secondary batteries, then electrical safety is improved, but mechanical safety against external forces and swelling remains insufficient
Solution Approach 1:
The patent introduces a cushioning member positioned between the battery cell and the case to absorb external forces before they reach the battery cell. This beforehand cushioning prevents mechanical damage from impacts and swelling, complementing the electrical safety systems and addressing the insufficiency of conventional safety approaches against mechanical hazards.
2Productivity
If battery cells are tightly packed in the battery pack to increase energy density, then productivity is improved, but heat dissipation becomes insufficient leading to temperature increase
Solution Approach 1:
The patent introduces a coolant flow channel as an intermediary space between the battery cells and the case. This mediator allows coolant to circulate and absorb heat from the battery cells, enabling tight packing for high energy density while maintaining effective heat dissipation through the coolant circulation path.
3Strength
If the battery pack case is made rigid to protect against external forces, then strength is improved, but shock absorption capability decreases
Solution Approach 1:
The patent places a cushioning member between the battery cell and the rigid case to absorb shocks before they reach the cell. This allows the case to maintain its rigid structure for protection while the cushioning member provides the necessary shock absorption capability through its elastic or viscoelastic properties.
4Reliability
If insulation members are added to improve insulativity and shock absorption, then safety is improved, but device complexity increases
Solution Approach 1:
The patent designs the insulation member to serve multiple functions simultaneously: providing electrical insulation between components, absorbing shocks and external forces, and defining coolant flow channels. This multi-functionality improves safety without proportionally increasing structural complexity, as one component accomplishes what would otherwise require multiple separate elements.
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 significantly improves the safety and cooling efficiency of battery packs by securely absorbing external shocks and facilitating coolant flow, reducing the risk of fires or explosions and maintaining the battery pack's integrity under stress conditions.
Implementation Method 1
an insulation member disposed between the battery module array and each of the end plates, the insulation member being provided at a surface thereof facing the battery module array with one or more ribs to absorb shock caused by external force
Implementation Method 2
the insulation member being provided at a surface thereof facing the battery module array with one or more ribs to absorb shock caused by external force and to define a coolant flow channel
Data Source
AI summary
Disclosed is a battery pack including a battery module array constituted by one or more battery modules each including one or more unit modules each configured to have a structure in which a battery cell is surrounded by a cell cover are mounted in a module case in a state in which the unit modules are stacked while being vertically upright, a base plate on which the battery module array is loaded, a pair of end plates to support opposite sides of the array in a state in which a lower end of each of the end plates is fixed to the base plate, and an insulation member disposed between the array and each of the end plates, the insulation member being provided at a surface thereof facing the array with one or more ribs to absorb shock caused by external force and to define a coolant flow channel.