Battery Module Filler Structure for Thermal Propagation Blocking
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Solution Overview
Problem
Conventional battery modules face challenges in efficiently securing safety against heat or fire propagation due to narrow spaces between battery cells, leading to potential serial explosions and high costs associated with fire prevention materials.
Innovation Solution
A battery module design incorporating a polymer member and a filler with particles, where the polymer member is a silicon resin and the filler includes various materials like plastic or ceramic particles, dispersed within the polymer to form a barrier against heat and flame propagation, reducing the need for expensive silicon resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a battery module uses a large number of battery cells, then the output power and energy are improved, but the module size increases and integration with the vehicle body becomes difficult
Solution Approach 1:
The battery module divides the large number of battery cells into multiple stacks, with each stack containing a subset of cells. This segmentation allows the module to maintain a high total cell count for sufficient power and energy while organizing them in a structured, space-efficient layout that facilitates compact integration with the vehicle body.
2Quantity of substance
If a battery module uses a large number of battery cells, then the output power and energy are improved, but the number of connection tabs increases leading to complex assembly and higher costs
Solution Approach 1:
Multiple battery cells within each stack share common connection tabs at their ends. Instead of requiring individual connection tabs for each cell, the design merges the electrical connections by having adjacent cells in a stack connect to shared tabs, significantly reducing the total number of connection tabs needed while maintaining all necessary electrical pathways for high power and energy output.
3Power
If battery cells are connected in parallel to increase current, then the output power is improved, but the connection tab area increases leading to more welding sites and higher costs
Solution Approach 1:
The patent transitions from increasing power solely through parallel connections (which require larger tab areas) to a three-dimensional stack configuration. By arranging cells in vertical stacks and utilizing multiple stacks connected in parallel, the design achieves high current output while maintaining compact connection tab areas, as the stacking arrangement optimizes space utilization and reduces the lateral footprint of connection interfaces.
Data Source
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AI summary
The present disclosure discloses a battery module whose safety is efficiently improved. The battery module according to the present disclosure to accomplish this object includes a plurality of battery cells; a module case having an inner space formed therein and configured to accommodate the plurality of battery cells in the inner space; a polymer member configured to be filled in at least a part of the inner space of the module case accommodating the plurality of battery cells; and a filler at least partially located inside the polymer member and interposed in at least one space of a space between at least one of the plurality of battery cells and the module case and a space between the plurality of battery cells.