Battery Module Side Separator Layout Against Capillary Short Circuits
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Solution Overview
Problem
Battery modules are prone to short circuits due to dew condensation water and external water ingress, which compromises their reliability.
Innovation Solution
A battery module design featuring a restraining member with a flat portion and a side separator that includes a first portion interposed between batteries to create a gap large enough to suppress water movement by capillarity, combined with a drainage channel to quickly remove any water, thereby preventing conductive paths and enhancing insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spacer members are used to insulate batteries from each other and from bind bars, then insulation properties are improved, but water can still cause short circuits through capillary action in the gaps
Solution Approach 1:
A waterproofing member (seal member) is introduced as an intermediary component between the battery pack case and the insulating member. This seal member fills the gap and prevents water from reaching the insulating member through capillary action, while the insulating member itself remains in place to provide electrical insulation. The combination of these two intermediary elements solves both the insulation requirement and the water prevention requirement.
Solution Approach 2:
The waterproofing member is implemented as a flexible seal member that can conform to the gap between the battery pack case and the insulating member. This flexible thin film structure effectively blocks water pathways while allowing the rigid insulating member to maintain its positioning and insulation function.
2Reliability
If batteries are stacked with spacer members to ensure insulation, then electrical insulation is improved, but water movement through capillarity can still occur
Solution Approach 1:
The waterproofing member acts as a mediator that blocks water pathways while the insulating member maintains electrical isolation. Together they create a dual-function barrier system that addresses both water prevention and electrical insulation without compromising either function.
Solution Approach 2:
The insulation and waterproofing functions are segmented into separate components: the insulating member handles electrical isolation while the waterproofing member handles water prevention. This segmentation allows each component to be optimized for its specific function while working together to solve the overall problem.
3Volume of moving object
If a compact battery module design is used, then space efficiency is improved, but water ingress risk increases
Solution Approach 1:
The waterproofing member is strategically placed at the interface between the battery pack case and the insulating member, creating a seal that prevents water ingress into the compact module. This allows the module to maintain its compact design while adding a targeted waterproofing barrier where water is most likely to enter.
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 design effectively prevents short circuits caused by water, ensuring improved reliability and efficient water discharge, thus enhancing the overall performance and safety of the battery module.
Implementation Method 1
the gap being large enough to suppress movement of water due to capillarity
Data Source
AI summary
Battery module includes battery stack having a plurality of batteries stacked, each battery having a top surface provided with an output terminal, restraining member that has flat portion extending along side surfaces of the plurality of batteries in stacking direction of batteries and restrains the plurality of batteries, and side separator that has first portion interposed between each battery and flat portion and insulates each battery from flat portion. Each battery is disposed with gap from first portion, the gap being large enough to suppress movement of water due to capillarity.