Foam-Filled Battery Module Structure for Impact-Stable Cylindrical Cells

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Solution Overview

Problem

Conventional battery modules experience instability and damage to battery cells due to external impacts, as gaps between cylindrical cells lead to movement and potential damage during such events.

Innovation Solution

A battery module design incorporating a module case, bus bar members, support plates, and foam members to stabilize battery cells, using a dispenser unit for foam injection and guide holes for uniform distribution, enhancing stability and impact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a plurality of cylindrical battery cells are stacked to form a battery module, then the battery module can be configured with series or parallel connections to achieve required output voltage and charge/discharge capacity, but gaps are generated between the cells which cause instability and potential damage during external impacts

Engineering Contradiction:

Improveoutput voltage and charge/discharge capacity configurationVSAvoidbattery cell stability under external impact

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent introduces a foam member that is injected into gaps between battery cells before the module is finalized. This foam member acts as a cushioning material that prevents direct contact and potential damage between cells during external impacts, thereby resolving the reliability issue while maintaining the adaptable configuration of cylindrical cells for various output voltages and capacities

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If a predetermined gap is generated between cylindrical battery cells according to their structural shape, then the cells can be easily assembled and manufactured, but the battery cells frequently move from/to each other during external impacts increasing damage concern

Engineering Contradiction:

Improveassembly of cylindrical cellsVSAvoidcell movement and damage during impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The foam member serves as an intermediary substance that is injected into the gaps between cylindrical battery cells. It fills the spaces that naturally exist due to the cylindrical shape, preventing cell movement during impacts while maintaining the ease of assembly advantage. The foam acts as a mediator that converts the harmful gap space into a protective cushioning layer

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides stable support and protection against external impacts, reducing the risk of battery cell damage and improving safety in battery modules, packs, and vehicles.

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 EffectFoam cushioning: Foam

Data Source

PatentUS12438223B2Battery module, and battery pack and vehicle including battery module

Publication Date: 2025.10.07 LG ENERGY SOLUTION LTD

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.