Elastic Battery Module Frame for Swelling and Cooling Control
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Solution Overview
Problem
Existing battery modules face issues with decreased battery density due to the need for separate fixing members, complex manufacturing processes, and insufficient absorption of battery cell deformation during charging and discharging, leading to swelling and module deformation.
Innovation Solution
A battery module design featuring an exterior member made of an elastic material surrounding the battery cell stack with sensing blocks and slits for electrode leads, along with compressive pads and thermally conductive resin layers, which enhances cooling performance and prevents swelling by absorbing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fixing members are used to secure the battery cell stack, then the battery module has sufficient structural support, but the battery density decreases due to space occupied by fixing members and manufacturing complexity increases
Solution Approach 1:
The module frame is designed to integrate both the support function and the fixing function into a single structure. The module frame includes integrated fixing members that are formed as part of the frame structure itself, eliminating the need for separate fixing components and reducing assembly steps while maintaining structural support and battery density
2Reliability
If compressive pads are used to press the battery cell stack, then the battery cells are secured, but a separate pressing process is required which complicates manufacturing
Solution Approach 1:
The pressing force is applied through the module frame structure itself during assembly, rather than requiring a separate pressing process. The module frame is designed with built-in pressing mechanisms that apply continuous compressive force to the battery cell stack as part of the normal assembly operation, eliminating the need for dedicated pressing equipment and processes
3Reliability
If traditional module frames are used, then the battery cell stack is protected, but cooling performance is insufficient and battery cell deformation is not adequately absorbed
Solution Approach 1:
An exterior member made of elastic material is used to surround the battery cell stack. This elastic exterior member can deform to accommodate battery cell expansion and contraction during charging and discharging cycles, providing continuous protection while maintaining pressure for thermal contact. The flexibility of the elastic material allows it to absorb deformation without compromising the protective function or thermal management effectiveness
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 improves cooling performance, prevents battery cell swelling, and simplifies the manufacturing process by eliminating the need for separate fixing members and pressing processes, while maintaining dimensional stability and increasing energy density.
Implementation Method 1
an exterior member made of an elastic material and configured to surround front and rear sides and two opposite lateral sides of the battery cell stack
Implementation Method 2
thermally conductive resin layers, which enhances cooling performance
Data Source
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AI summary
An exemplary embodiment of the present invention provides a battery module including: a battery cell stack including a plurality of battery cells stacked in a first direction; an exterior member configured to surround front and rear sides and two opposite lateral sides of the battery cell stack; and sensing blocks positioned at front and rear sides of the battery cell stack, in which the sensing blocks are positioned between the exterior member and the front and rear sides of the battery cell stack, and in which upper and lower sides of the battery cell stack are exposed.