Battery Pack Spacer for Vibration and Condensation Control
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Solution Overview
Problem
Existing battery packs fail to securely stabilize battery modules against external impacts and vibrations, and are vulnerable to condensed water due to temperature differences, leading to potential malfunctions.
Innovation Solution
A battery pack design incorporating a spacer between the pack housing and battery modules to restrain motion and prevent water ingress, featuring a polymer resin foam spacer with closed pores and a structural configuration that includes tension bars and a battery management system to ensure stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a tension bar is mounted at the upper ends of the battery modules to prevent motion, then motion in the arrangement direction is prevented, but motion in the lateral direction cannot be sufficiently prevented and the structure does not protect against condensed water
Solution Approach 1:
The patent introduces a buffer member as an intermediary component between the battery modules and the pack housing. This buffer member serves multiple functions: it prevents lateral motion of battery modules, blocks condensed water from reaching battery modules, and absorbs vibration. By adding this intermediary element, the patent resolves the limitation of the tension bar structure which could only prevent motion in one direction.
Solution Approach 2:
The buffer member is designed to perform multiple functions simultaneously: mechanical support to prevent lateral motion, thermal insulation to block condensed water, and vibration damping. This multi-functional approach allows a single component to address multiple problems (lateral motion, water ingress, vibration) that the previous tension bar structure could not handle comprehensively.
2Ease of manufacture
If empty space is provided between the pack housing and battery modules, then assembly is easier, but condensed water can fall to the upper ends of battery modules causing malfunction
Solution Approach 1:
The buffer member acts as an intermediary barrier between the pack housing and battery modules. It fills the space that would otherwise allow condensed water to accumulate and reach the battery modules. The buffer member's material properties (hydrophobic, closed-cell foam) specifically address the condensed water issue while maintaining the beneficial assembly clearance.
Solution Approach 2:
The patent specifies using closed-cell foam material for the buffer member. This porous structure provides thermal insulation to prevent condensation formation and the closed cells prevent water absorption. The material choice directly addresses the condensed water problem while maintaining structural integrity and ease of installation.
3Quantity of substance
If battery modules are stacked adjacent to each other on a base plate, then high capacity and output are achieved, but vibration causes motion of battery modules leading to instability
Solution Approach 1:
The buffer member is installed beforehand between the battery modules and pack housing to provide cushioning against vibration and motion. This preventive measure absorbs vibrational energy before it can cause battery module displacement, maintaining stability while allowing the high-density stacking configuration for maximum capacity and output.
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 spacer effectively stabilizes battery modules during external impacts and vibrations, while preventing condensed water from entering the pack, thereby enhancing the reliability and durability of the battery pack.
Implementation Method 1
a spacer (170) disposed in a space defined between an inner surface of the pack housing (160) and upper, outer surfaces of the battery modules (110) to restrain motion of upper end parts of the battery modules
Implementation Method 2
featuring a polymer resin foam spacer with closed pores
Data Source
AI summary
Disclosed herein is a battery pack configured to have a structure in which two or more battery modules, each of which includes a plurality of battery cells or unit modules which can be charged and discharged, are arranged such that the battery modules are mounted in a space defined between a pack housing and a base plate, the battery pack including the base plate on which the arranged battery modules are loaded, a sensing assembly mounted at upper ends of the battery modules for detecting voltage of the battery modules, a pair of tension bars mounted at the upper ends of the battery modules in a direction in which the battery modules are arranged for supporting the battery modules, a battery management system (BMS) mounted at an outside of an outermost one of the battery modules in a state in which the BMS is adjacent to the outermost one of the battery modules, the pack housing for surrounding the battery modules and the BMS, a lower end of the pack housing being coupled to the base plate, and a spacer disposed in a space defined between an inner surface of the pack housing and outer surfaces of the battery modules for restraining motion of upper end parts of the battery modules.