Cylindrical Battery Module Potting Seal Against Moisture Ingress
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Solution Overview
Problem
Existing secondary battery modules fail to effectively prevent moisture ingress, leading to corrosion of cells due to factors like high temperature, humidity, and temperature changes, which compromises long-term reliability.
Innovation Solution
A secondary battery module design that applies potting material to the top surfaces of cylindrical cells and the cell holder, sealing the cells and holder to prevent moisture ingress, while avoiding costly tubing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing structures are used, then moisture ingress is not effectively prevented, but the structure remains simple
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated sealing structure that seals both the gap between the cell holder and case, and the top surfaces of the cells simultaneously. This merging of sealing functions resolves the contradiction by providing effective corrosion prevention without requiring multiple separate sealing components or complex assembly steps.
Solution Approach 2:
The patent introduces a sealing member as an intermediary component between the cell holder/cells and the case. This sealing member acts as a mediator that effectively blocks moisture ingress paths without requiring complex modifications to the existing cell holder or case structures, thus improving reliability while maintaining relatively simple device complexity.
2Reliability
If tubing process is applied to cylindrical cells, then corrosion prevention is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the sealing function from the individual cell level (where tubing would be applied) and relocates it to the module level using a sealing member in the cell holder. This extraction eliminates the need for costly and complex tubing processes on each cell while achieving the same corrosion prevention goal, thus resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent replaces the expensive and labor-intensive tubing process with a simpler, more cost-effective sealing member that can be easily manufactured and installed. The sealing member provides equivalent corrosion protection without the high manufacturing costs and complexity associated with tubing, resolving the contradiction between reliability and ease of manufacture.
3Object-affected harmful factors
If outer casing alone is used for sealing, then device simplicity is maintained, but moisture protection is insufficient
Solution Approach 1:
The patent segments the sealing function into two distinct parts: the outer casing that provides structural enclosure, and the sealing member that provides the actual moisture barrier. This segmentation allows each component to be optimized for its specific function, with the sealing member targeting specific moisture ingress paths at the cell holder and cell top surfaces, thereby improving moisture protection without requiring complete redesign of the entire sealing structure.
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 effectively prevents corrosion of cells, simplifies the manufacturing process, and reduces costs by sealing the cells without tubing, while also providing insulation and preventing ignition spread.
Implementation Method 1
potting material is applied to at least a portion of top surfaces of the plurality of cylindrical cells and a surface of the cell holder to seal the plurality of cylindrical cells and the cell holder
Implementation Method 2
potting material is applied to at least a portion of top surfaces of the plurality of cylindrical cells and a surface of the cell holder to seal the plurality of cylindrical cells and the cell holder
Data Source
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AI summary
A secondary battery module may include a plurality of cylindrical cells, a cell holder holding the plurality of cylindrical cells, and a first case accommodating the plurality of cylindrical cells and the cell holder. The first case may include an open side, wherein potting material may be applied to at least a portion of top surfaces of the plurality of cylindrical cells and a surface of the cell holder to seal the plurality of cylindrical cells and the cell holder.