Cylindrical Battery Module Foam Filling for Cell Gap Stabilization

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Solution Overview

Problem

Conventional battery modules experience instability and damage from external impacts due to gaps between cylindrical cells, necessitating improved support and protection.

Innovation Solution

A battery module design incorporating a module case with cylindrical cells, bus bar members, a support plate, and a foam member filled between cells to stabilize and prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cylindrical cells are stacked with gaps between them, then the cells can be easily assembled and manufactured, but the cells become unstable and vulnerable to damage from external impacts

Engineering Contradiction:
Improveease of assemblyVSAvoidstability of cells
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

A foam member is pre-filled in the module case to occupy the gaps between cylindrical battery cells before the cells are installed. This foam member acts as a cushioning material that prevents the cells from moving or colliding with each other during operation, thereby stabilizing the cells while maintaining the ease of assembly process.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If a support structure is added to prevent cell movement, then cell stability improves, but device complexity increases

Engineering Contradiction:
Improvestability of cellsVSAvoidstructural complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

A foam member with porous structure is used to fill the gaps between battery cells. The foam material provides support and stabilization functionality while occupying minimal space and integrating seamlessly into the existing module structure, thus improving cell stability without significantly increasing device complexity.

Inventive Principle:
Principle #31Porous materials

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 enhances stability and safety by preventing cell movement and damage from external impacts, improving manufacturing efficiency and safety.

Implementation Method 1

a foam member filled in a space between the plurality of battery cells at a bottom portion of the support plate

Methodology Applied
Scientific EffectPhysical cushioning:

Data Source

PatentUS12374745B2Battery module, and battery pack and vehicle including battery module
Publication Date: 2025.07.29 LG ENERGY SOLUTION LTD
  • US12374745B2 patent drawing
  • US12374745B2 patent drawing
  • US12374745B2 patent drawing

AI summary

Disclosed is a battery module, which includes a module case having a predetermined accommodation space; a plurality of battery cells accommodated in the module case; a plurality of bus bar members provided at an upper side of the plurality of battery cells to electrically connect the plurality of battery cells; a support plate disposed between the plurality of battery cells and the plurality of bus bar members to support the plurality of bus bar members; and a foam member filled in a space between the plurality of battery cells at a bottom portion of the support plate.