Battery Module Interlocking Blocks with Metal Plate Pressure Isolation
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Solution Overview
Problem
Existing battery modules for electric cars and other applications lack sufficient safety measures to prevent accidents caused by gas release and pressure buildup during cell operation.
Innovation Solution
A battery module design featuring interlocking battery blocks with aligned electrodes and metal plates, where projections from one block contact the metal plates of adjacent blocks to secure alignment and prevent gas-induced pressure transfer, along with a housing system that includes exhaust ducts and reinforced components to manage gas release and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If cells are interconnected in parallel to form battery blocks and stacked to form battery modules, then the power output and energy storage capacity are improved, but the safety risk increases due to potential gas release and pressure buildup affecting adjacent cells
Solution Approach 1:
The battery module is segmented into multiple independent battery blocks, each enclosed in a separate holder. This segmentation isolates potential gas release and pressure buildup to individual blocks, preventing propagation to adjacent blocks while maintaining high power output through parallel connection of multiple blocks.
Solution Approach 2:
A metal plate is introduced as an intermediary component between adjacent battery blocks. The metal plate serves as a barrier that prevents gas and pressure from transferring between blocks, while still allowing thermal energy dissipation. This intermediary structure resolves the contradiction by enabling high-density packing for power output while maintaining safety through pressure isolation.
2Quantity of substance
If battery blocks are arranged adjacently to increase energy density, then the space utilization is improved, but the risk of gas-induced pressure transfer between blocks increases
Solution Approach 1:
The metal plate acts as a mediator between adjacent battery blocks, allowing them to be arranged closely for high energy density while blocking the transfer of gas-induced pressure. The plate is positioned in the pressure release path of each block, preventing harmful pressure propagation to neighboring blocks.
Solution Approach 2:
The design converts the harmful effect of gas release by directing it through a controlled path to the metal plate, where the gas can safely escape without affecting adjacent blocks. The pressure release mechanism is transformed from a safety hazard into a controlled venting system that maintains block independence.
3Manufacturing precision
If projections are added to block holders to prevent misalignment, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
Projections are added to the block holders at specific asymmetric positions that correspond to recesses or features on adjacent blocks. This asymmetric design provides foolproof alignment, ensuring that blocks can only be assembled in the correct orientation, thereby achieving high alignment precision with minimal additional structural complexity.
Data Source
AI summary
A battery module includes a plurality of battery blocks. Each battery block includes: a cell assembly including a plurality of cells; a block holder for holding the cell assembly; and a metal plate. The plurality of cells are held in the block holder while the positive electrodes and negative electrodes of the cells are aligned. A projection or the metal plate is disposed outside the block holder. The tip of the projection of one of adjacent battery blocks is in contact with the metal plate of the other.