Flexible Foldable Enclosure for Battery Module Space Efficiency
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Solution Overview
Problem
Existing battery modules, particularly lithium-ion batteries, face challenges in flexibility, space efficiency, and reliability due to rigid enclosures and potential for corrosion and short circuits, which limits their adaptability and longevity in various applications.
Innovation Solution
A battery module comprising a flexible, foldable enclosure with pouch cells and a composite film that is moisture-permeable or impermeable, using materials like aluminum, steel, or polyphenylene sulfide, which allows for customizable configuration, prevents corrosion, and reduces the risk of short circuits, while also being cost-effective and adaptable to different temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid enclosures are used for battery modules, then structural strength and protection are improved, but flexibility and space efficiency deteriorate
Solution Approach 1:
The patent employs a flexible pouch film enclosure instead of rigid housing to contain the battery cells. This flexible membrane provides necessary protection while allowing the battery module to be configured in various shapes and orientations, thereby resolving the contradiction between structural strength and flexibility.
Solution Approach 2:
The battery module design allows dynamic configuration through the flexible enclosure, enabling adaptation to different spatial requirements in portable devices. The pouch structure can be folded and shaped to optimize space utilization while maintaining protective integrity.
2Ease of manufacture
If traditional enclosures are used, then manufacturing simplicity is improved, but corrosion resistance and short circuit prevention deteriorate
Solution Approach 1:
The pouch film is constructed as a composite material structure with multiple layers including aluminum foil for corrosion resistance, plastic layers for sealing, and protective coatings. This composite approach provides enhanced reliability against corrosion and short circuits while maintaining manufacturing feasibility through established lamination processes.
3Adaptability or versatility
If pouch cells are used instead of rigid cells, then space efficiency and adaptability are improved, but structural protection deteriorates
Solution Approach 1:
The flexible pouch film serves as both the structural enclosure and protective element for the soft pouch cells. While the cells lack rigid housings, the multi-layer pouch film provides necessary mechanical protection, chemical resistance, and electrical insulation, balancing the reduced structural strength with improved space efficiency.
Data Source
AI summary
A battery module (100) comprising at least one battery cell system (1) having at least two battery cells (11), wherein the battery cell system (1) comprises a pouch film (3) and at least two electrode composites (5), wherein an electrode composite (5) comprises at least one anode and at least one cathode, and wherein the pouch film (3) forms pockets (12) separated from one another, in particular situated alongside one another, for introducing respectively at least one electrode composite (5), such that each pocket (12) together with electrode composite (5) forms a pouch cell (10), and wherein the pockets (12) are connected to one another physically in a foldable manner via the pouch film (3) and wherein the battery module (100) has a movement-flexible, foldable enclosure (20), which encloses the entire battery cell system (1) and the voltage tap of the battery module (100).