Battery Pack Cell Filling Structure for Chain Ignition Resistance
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Solution Overview
Problem
Conventional battery packs face issues with chain ignition and reduced space efficiency due to gaps between battery cells and the need for additional module cases and frames.
Innovation Solution
A battery pack design that includes a pack case, a battery cell assembly with a resin layer filling the lower space and an inorganic film filling the upper space between battery cells, formed through forced phase separation of a composition containing a base resin and an inorganic filler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a module case and frame are used to accommodate battery cells, then structural support is provided, but the weight of the battery pack increases and space efficiency decreases
Solution Approach 1:
The patent removes the module case and frame structures from the battery pack design. Instead of using separate structural components, the battery cells are directly accommodated in the pack case, eliminating unnecessary structural elements that add weight and reduce space efficiency.
Solution Approach 2:
The patent merges the structural support function into the pack case itself, which is made from a foam material that provides both structural integrity and cell accommodation. This consolidation eliminates the need for separate module cases and frames, reducing overall weight while maintaining structural support.
2Strength
If a module case and frame are used to accommodate battery cells, then structural support is provided, but the space efficiency within the battery pack decreases
Solution Approach 1:
The patent removes the module case and frame structures that occupy unnecessary space within the battery pack. By eliminating these intermediate structural components, more volume is available for battery cells, improving space efficiency.
Solution Approach 2:
The structural support function is merged into the pack case foam material, which directly contacts and supports the battery cells. This eliminates the need for separate frames and module cases, maximizing the usable volume within the battery pack.
3Strength
If gaps between battery cells are filled with frame ribs or left as empty space, then structural support is provided, but the possibility of chain ignition increases
Solution Approach 1:
The patent applies a foam material with specific properties throughout the pack case that simultaneously provides structural support and flame retardancy. The foam's cellular structure offers mechanical support while its material composition prevents flame propagation, addressing both requirements with a single material solution.
Solution Approach 2:
The pack case is constructed from a foam material that combines structural and safety functions. This composite material provides both the mechanical support needed for cell accommodation and the flame-retardant properties that prevent chain ignition, replacing the need for separate structural and safety 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 prevents side rupture of battery cells, secures structural rigidity, reduces the possibility of chain ignition, and enhances space efficiency within the battery pack.
Implementation Method 1
a resin layer filling a relatively lower portion of the space between the plurality of battery cells and an inorganic film filling a relatively upper portion of the space between the plurality of battery cells, formed through forced phase separation of a composition containing a base resin and an inorganic filler
Data Source
AI summary
A battery pack includes a pack case, a battery cell assembly, a resin layer, and an inorganic film. The battery cell assembly includes a plurality of battery cells accommodated in the pack case; and the resin layer fills a relatively lower portion of a space between the plurality of battery cells. The inorganic film fills a relatively upper portion of the space between the plurality of battery cells. A method of manufacture is also provided.