Battery Module Resin Layer for Impact and Thermal Runaway Containment
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Solution Overview
Problem
Existing battery modules face challenges in mounting flexibility due to directional restrictions and are prone to chain reactions of fire outbreaks upon thermal runaway, especially when impacted externally.
Innovation Solution
A battery module design featuring a resin layer that fills empty spaces, a thermally conductive pad with integrated heat dissipation, and strategically positioned space portions to minimize movement and contain thermal events, allowing flexible installation and reducing fire spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If empty spaces are left in the battery module for wire routing and rib structure, then ease of manufacture and electrical connection are improved, but impact resistance and structural stability deteriorate
Solution Approach 1:
The patent fills the empty spaces between battery cells with a filling material that combines structural support functions with space utilization. This merging approach allows the filling material to simultaneously provide impact resistance and maintain the necessary space for electrical connections, resolving the contradiction between ease of manufacture and impact resistance.
Solution Approach 2:
The filling material is applied specifically in the empty spaces between battery cells, providing localized reinforcement where impact resistance is most needed. This local quality approach allows the battery module to maintain ease of manufacture in other areas while selectively improving impact resistance in critical regions.
2Ease of operation
If empty spaces are provided for wire bonding operations, then ease of operation is improved, but fire spread resistance deteriorates due to space for flame propagation
Solution Approach 1:
The filling material acts as an intermediary substance between battery cells, filling the empty spaces that would otherwise allow flame propagation. This intermediary material provides a fire barrier while still allowing necessary electrical connections to be made, resolving the contradiction between ease of operation and fire spread resistance.
Solution Approach 2:
The filling material is strategically placed in empty spaces to provide localized fire protection. This local quality approach maintains ease of operation for wire bonding in accessible areas while blocking fire spread paths in critical spaces between battery cells.
3Manufacturing precision
If battery cells are arranged in a fixed directional configuration, then manufacturing precision is improved, but adaptability deteriorates due to mounting direction restrictions
Solution Approach 1:
The filling material provides universal adaptability by being compatible with various battery cell arrangements and mounting orientations. It fills spaces regardless of the specific configuration, allowing the battery module to be manufactured with precision while maintaining adaptability to different mounting directions and applications.
Solution Approach 2:
The filling material is applied in segmented portions between individual battery cells, allowing each cell to maintain its precise manufacturing tolerances while the overall module gains adaptability through the flexible filling approach that accommodates various configurations.
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 enhances impact resistance, enables flexible mounting, and minimizes fire propagation by containing thermal events within the module, thereby improving safety and efficiency.
Implementation Method 1
a resin layer (700) provided above the plurality of battery cells (300)
Implementation Method 2
a pad (800) located between the resin layer (700) and the second case (200)
Data Source
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AI summary
The present invention relates to a battery module with improved impact resistance and safety and a battery pack including the same, and more particularly to a battery module including a first case having a receiving space, a plurality of battery cells received in the receiving space in an upright state such that a positive electrode terminal of each of the plurality of battery cells faces upwards, one or more busbars located in the vicinity of the positive electrode terminals of the plurality of battery cells, a wire configured to electrically connect each of the plurality of battery cells and the one or more busbars to each other, a rib structure located above the plurality of battery cells, the rib structure being provided with an upwardly protruding rib configured to protect the wire and an opening configured to allow the wire to extend therethrough, and a resin layer provided above the plurality of battery cells, and a battery pack including the same.