Battery Module Disconnect Structure for Swelling Protection
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Solution Overview
Problem
Soft pack lithium batteries can experience swelling due to gas production, leading to potential safety hazards if not controlled, as uncontrolled swelling can result in explosion.
Innovation Solution
A battery module design featuring a shell, battery cell assembly, circuit board, conductive assembly, and a movable structural member that disconnects the conductive members when the battery cell assembly swells, thereby disconnecting the main circuit to prevent further swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery cell assembly is used without a protective mechanism, then the device complexity is reduced, but the safety and reliability deteriorate due to uncontrolled swelling leading to explosion hazards
Solution Approach 1:
The battery cell assembly itself serves as the triggering mechanism for circuit disconnection. When swelling occurs, the battery assembly directly pushes the movable structural member through its own expansion force, eliminating the need for external sensors or detection devices. This self-service approach enhances safety while minimizing additional components.
Solution Approach 2:
A movable structural member acts as an intermediary between the battery cell assembly and the conductive members. This intermediary component translates the physical swelling of the battery into mechanical motion that disconnects the circuit, providing a simple yet effective safety mechanism without complex electronic control systems.
2Reliability
If a movable structural member is added to disconnect conductive members during swelling, then the safety is improved, but the device complexity increases
Solution Approach 1:
The structural member transitions from a static component to a dynamic one that can move in response to battery swelling. This dynamic characteristic allows the system to automatically adapt to abnormal conditions without requiring complex control logic or multiple active components, maintaining simplicity while enhancing safety responsiveness.
Solution Approach 2:
The conductive path is segmented into separable conductive members that can be physically disconnected. This segmentation allows the safety mechanism to function by simply separating two conductive parts when swelling occurs, avoiding the need for complex switching mechanisms or electronic control systems.
3Object-affected harmful factors
If the conductive members are kept permanently connected, then the electrical conductivity is maintained, but the harmful factors increase due to continued gas production and heat transfer during swelling
Solution Approach 1:
The movable structural member is pre-positioned to automatically disconnect the conductive members when swelling reaches a critical threshold. This preliminary anti-action prevents the harmful effects of continued gas production and heat transfer by interrupting the electrical circuit before the swelling becomes uncontrollable, rather than attempting to manage the swelling after it has started.
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 solution effectively controls battery cell swelling by disconnecting the main circuit when swelling occurs, reducing the risk of explosion and ensuring safety by preventing further gas buildup and heat transfer.
Implementation Method 1
internal battery cells will produce gas and subsequently swell
Data Source
AI summary
A battery module includes a shell, a battery cell assembly disposed in the shell, a circuit board, a conductive assembly, and a first structural member. The circuit board is electrically connected to the battery cell assembly; the conductive assembly is electrically connected to the circuit board, and the conductive assembly includes a first conductive member and a second conductive member; and the first structural member is disposed on a side of the battery cell assembly adjacent to the conductive assembly, and the first structural member is movable in a first direction, such that the first conductive member is connected to or separated from the second conductive member, the first direction being a direction from the battery cell assembly to the circuit board.