Battery Module Sealing via Insulating Outer Frame
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Solution Overview
Problem
Existing battery modules face challenges in securely sealing battery elements due to increased internal pressure during charging or discharging, which can lead to gas leakage, and require careful handling to prevent accidental load-induced gaps between resin components.
Innovation Solution
A battery module design featuring an insulating frame body with conductive plates and an insulating outer peripheral frame body that covers the battery element without joining resin components, using insert molding to form the outer peripheral frame body and ensuring electrical continuity between plates and collector foils for easy sealing and stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin components are joined and welded to seal the battery element, then sealing effectiveness is improved, but the complexity of the sealing process increases and the risk of gas leakage at joint positions increases
Solution Approach 1:
The invention extracts and eliminates the resin component joining process from the sealing system. Instead of using multiple resin parts that require welding and bonding, the seal is achieved through the mechanical interference fit between the battery element case and the battery module housing, with the elastic member providing sealing pressure. This removes the complex resin joining operations entirely.
Solution Approach 2:
The invention introduces an elastic member as an intermediary sealing element between the battery element case and the battery module housing. This elastic member deforms to fill gaps and provide sealing pressure, acting as a mediator that achieves reliable sealing without requiring precise welding or bonding of rigid components.
2Reliability
If resin components are securely welded to prevent gas leakage, then sealing reliability is improved, but the difficulty of handling and assembly increases
Solution Approach 1:
The invention segments the sealing function from the structural function. The hard components (battery element case and module housing) provide structural support and positioning, while the elastic member separately provides the sealing function. This segmentation allows each component to be optimized for its specific function and simplifies assembly.
Solution Approach 2:
The invention changes the physical state and properties of the sealing element by using an elastic material that can deform under compression. The elastic member's ability to change shape and provide continuous sealing pressure through deformation simplifies assembly compared to rigid welded joints, while maintaining reliable gas leakage prevention.
3Manufacturing precision
If careful handling is applied to prevent gaps between resin components, then sealing quality is improved, but the productivity of assembly decreases
Solution Approach 1:
The invention incorporates the elastic member as a pre-designed cushioning element that compensates for manufacturing tolerances and assembly variations. The elastic member's deformability provides a buffer that absorbs dimensional variations, ensuring consistent sealing quality without requiring extremely precise assembly operations.
Solution Approach 2:
The elastic member provides self-adjusting sealing through its elastic deformation properties. During assembly, the elastic member automatically deforms to fit the available space and provide sealing pressure, eliminating the need for operators to perform careful manual adjustments to ensure gap-free sealing between components.
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
This design simplifies the sealing process, enhances the strength of individual and stacked battery modules, and ensures reliable electrical connections between modules, reducing the risk of gas leakage and improving handling and assembly efficiency.
Implementation Method 1
an insulating outer peripheral frame body provided to cover outer peripheral plate sections of the first and second plates along a circumference in a frame shape to include circumferential end faces of the first and second plates and a circumferential end face of the frame body
Data Source
AI summary
An object of the invention is to provide an easy sealing technique of a battery element. A battery module has a battery element placed in the frame shape of an insulating middle frame body. This battery element is covered across the middle frame body by a positive electrode-side plate and a negative electrode-side plate to be contained. In the battery module, an insulating outer peripheral frame body is provided to cover outer peripheral plate sections of the positive electrode-side plate and the negative electrode-side plate along a circumference in a frame shape to include circumferential end faces of the positive and negative electrode-side plates and a circumferential end face of the middle frame body.