Battery Module Swelling Bypass Mechanism
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Solution Overview
Problem
Conventional battery modules in series configurations face safety risks due to unexpected power cuts when abnormal battery cells swell, leading to potential vehicle collisions during driving.
Innovation Solution
A battery module design featuring coupling units with an operation unit that ascends to open connections between terminals upon increased internal pressure, and a bypass unit that maintains series connections with other battery packs except for the failing ones, utilizing a shielding film and pressing unit to manage pressure and form a bypass circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a physical power cut off principle using volume inflation by swelling is applied to ensure safety, then battery safety is improved, but the battery system operation stops causing potential vehicle collision risks
Solution Approach 1:
The battery pack is divided into multiple independent battery modules, each with its own coupling unit and bypass unit. This segmentation allows individual modules to be isolated while others continue operating, maintaining system productivity while ensuring safety through localized power cut-off.
Solution Approach 2:
The bypass unit acts as an intermediary component that provides an alternative current path when a battery module fails. This mediator allows the battery system to maintain operation by routing current through functional modules, preventing complete system shutdown while safety mechanisms remain active.
2Reliability
If the coupling portion of electrode terminal is formed with a fragile structure to induce power cut off when swelling occurs, then power cut off reliability is improved, but the battery system cannot bypass abnormal cells causing operation stop
Solution Approach 1:
The coupling unit incorporates a movable operation unit that can dynamically change position in response to swelling pressure. This dynamic mechanism automatically opens the coupling connection when abnormal expansion occurs, providing reliable power cut-off while the bypass unit adapts to maintain system operation through alternative pathways.
Solution Approach 2:
The system utilizes parameter changes in battery module volume (swelling) as the trigger mechanism. When the volume expansion parameter reaches a critical threshold, it activates the operation unit to open the coupling, providing automatic power cut-off based on physical parameter changes while the bypass system adapts to maintain overall functionality.
3Difficulty of detecting and measuring
If a pressure switch for sensing gas generation due to swelling conditions is mounted to sense and respond to pressure variations, then detection capability is improved, but device complexity increases
Solution Approach 1:
The battery module utilizes its own physical swelling as the detection mechanism, eliminating the need for external sensors. The volume expansion directly actuates the operation unit through mechanical coupling, providing self-service detection that reduces system complexity while maintaining high detection capability for abnormal conditions.
Solution Approach 2:
The system replaces electronic sensing mechanisms (pressure switches, sensors) with a direct mechanical response system. The swelling battery module mechanically actuates the coupling unit opening through physical displacement, substituting complex electronic detection and control systems with a simpler mechanical actuation mechanism that achieves the same safety function.
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
Ensures continuous operation of the battery system by bypassing abnormal battery packs, preventing secondary collisions and maintaining series connections, thus enhancing vehicle safety by sensing and responding to internal pressure variations.
Implementation Method 1
an operation unit which is provided on one end of the coupling unit and ascends in accordance with an internal pressure increasing in the battery pack to open a coupling between the one end of the coupling unit and the terminals of the battery pack
Implementation Method 2
a bypass unit... to maintain the other battery packs connected in series except for the battery packs the internal pressures of which are increased
Data Source
AI summary
A battery module is provided, including: a plurality of battery packs teach being provided with an anode terminal and a cathode terminal; a plurality of coupling units each having ends coupled to the anode terminal and the cathode terminal of an adjacent battery pack, respectively, to couple the plurality of battery packs in series; an operation unit that is provided on one end of the coupling unit and ascends in accordance with an increasing internal pressure of the battery pack to open a coupling between the one end of the coupling unit and the terminals of the battery pack by raising the one end of the coupling unit; and a bypass unit having one end disposed over the one end of the coupling unit and the other end coupled to the other end of an adjacent coupling unit to maintain the other battery packs coupled in series, except for the battery packs the internal pressures of which have increased, when the one end of the coupling unit ascends by the operation unit.