Battery Module Construction With Reinforcing Divider
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Solution Overview
Problem
Batteries, particularly lithium-ion batteries, face challenges with mechanical vulnerability and thermal management issues, leading to reduced lifespan and instability due to temperature fluctuations and potential short circuits from physical damage.
Innovation Solution
A battery module design featuring a polymeric case with a monolithic, thermally-conductive reinforcing divider and shock dampening material, which provides structural reinforcement, thermal management, and protection against mechanical stress, while allowing for efficient heat transfer and electrical connectivity of lithium-ion pouch cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium-ion batteries are used to power transportation and utility apparatuses, then energy storage capacity is improved, but mechanical vulnerability and thermal instability increase
Solution Approach 1:
The patent employs a composite construction combining a polymeric battery case with an integrated reinforcing divider. The divider is formed from a composite material structure that includes a core layer sandwiched between two outer layers, creating a mechanically robust yet lightweight component that strengthens the battery case without significantly increasing weight.
Solution Approach 2:
The reinforcing divider is segmented into multiple functional layers: an inner layer, an outer layer, and a core layer positioned between them. This segmentation allows each layer to perform specific functions - the outer layers provide structural strength while the core layer provides thermal management capabilities, collectively addressing both mechanical vulnerability and thermal instability.
2Power
If battery operating temperature increases due to Joule heating, then energy conversion efficiency is maintained, but battery stability decreases and internal discharge increases
Solution Approach 1:
The core layer of the reinforcing divider incorporates a phase change material that absorbs excess heat from battery operation through phase transitions. This passive thermal management mechanism maintains battery temperature within stable operating ranges, preventing thermal runaway and internal discharge while preserving energy conversion efficiency.
Solution Approach 2:
The core layer acts as an intermediary thermal management component between the battery cells and the external environment. It mediates heat transfer by absorbing thermal energy through phase change, thereby stabilizing battery operating temperature and preventing harmful thermal effects.
3Strength
If reinforcing structures are added to protect battery cells, then mechanical strength is improved, but thermal management capability deteriorates
Solution Approach 1:
The reinforcing divider is designed as a multi-functional component that simultaneously provides mechanical strengthening and thermal management. The integrated structure combines load-bearing outer layers with heat-absorbing core layer, allowing a single component to address both structural reinforcement and thermal control needs of the battery system.
Solution Approach 2:
The patent merges the functions of structural reinforcement and thermal management into a single integrated reinforcing divider assembly. By combining the mechanically strong outer layers with the thermally active core layer, the design eliminates the need for separate reinforcement structures and thermal management systems.
4Ease of manufacture
If soft pouch battery cell construction is used, then manufacturing flexibility is improved, but mechanical protection capability deteriorates
Solution Approach 1:
The reinforcing divider is installed within the polymeric battery case before final assembly, creating a protective framework that cushions and protects the soft pouch battery cells from mechanical damage. This pre-positioned reinforcement structure maintains the manufacturing flexibility of soft pouch cells while adding necessary mechanical protection.
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 enhances the mechanical stability and thermal management of battery modules, extending their functional life by preventing physical damage and thermal instability, thus maintaining performance and safety.
Implementation Method 1
The shock dampening material is positioned between the reinforcing divider and the polymeric case and operable to dampen and transfer forces between the polymeric case and the reinforcing divider
Implementation Method 2
The monolithic, thermally-conductive, reinforcing divider includes a plurality of dividing wall members defining a plurality of cavities therebetween, with the cavities located within the polymeric case. The monolithic, thermally-conductive reinforcing divider also defines a plurality of thermal transfer projections received through respective ones of the openings of the polymeric case and providing thermal transfer members projecting externally of the polymeric case
Implementation Method 3
some lithium-ion batteries tend to increase temperature during operation due to Joule heating within the batteries
Data Source
AI summary
Described are mechanically robust, thermally managed battery module constructions including a battery case, a reinforcing divider in the case, and battery cells housed by the reinforcing divider. The reinforcing divider defines a plurality of thermal transfer elements externalized of the battery case. A shock dampening material can be provided between the reinforcing divider and the battery case to facilitate a mechanical, shock-dampened, reinforcing integration of the divider and case.