Foam-Filled Battery Module Structure for Cylindrical Cell Stability
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Solution Overview
Problem
Conventional battery modules are prone to damage from external impacts due to the gaps between cylindrical battery cells, which can cause the cells to shift and collide, leading to instability and potential damage.
Innovation Solution
A battery module design featuring a module case with a support plate and foam member to stabilize the cells, where the foam is injected between the cells using a dispenser unit and guide holes to fill the space, providing additional support and preventing movement during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a plurality of cylindrical battery cells are stacked to form a battery module, then the battery module can achieve required output voltage and charge/discharge capacity, but gaps are generated between the cells causing instability and potential damage from external impacts
Solution Approach 1:
The patent uses a foam filling member that expands to fill gaps between battery cells, providing flexible support and stabilization. The foam material conformally fills the spaces between cylindrical cells, preventing movement while accommodating thermal expansion and contraction.
Solution Approach 2:
The patent employs a composite structure combining rigid bus bar members for electrical connection with flexible foam filling material for mechanical support. This composite approach addresses both electrical functionality and mechanical stability requirements.
2Ease of manufacture
If conventional battery module structure is used with gaps between cylindrical cells, then assembly is simple, but external impacts cause cells to shift and collide leading to damage
Solution Approach 1:
The foam filling member is injected into the module case before final assembly, where it expands to pre-fill gaps and provide support. This preliminary action ensures cells are stabilized before any impact can occur, preventing shifting during operation.
Solution Approach 2:
The foam filling member acts as an intermediary between the battery cells and the external environment, absorbing impact forces and preventing direct contact between cells during shocks or vibrations.
3Stability of the object's composition
If foam member is injected between battery cells to fill gaps, then cell stability is improved, but additional manufacturing steps and equipment are required
Solution Approach 1:
The patent uses a dispenser unit that injects foam material in liquid or semi-liquid form through nozzles, utilizing pneumatic or hydraulic principles to distribute the material evenly between cells. The foam then expands to fill gaps, providing a simple yet effective stabilization method.
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 stabilizes battery cells by preventing them from shifting and reduces the risk of damage from external impacts, enhancing the safety and stability of the battery module, pack, and vehicle systems.
Implementation Method 1
a foam member filled in a space between the plurality of battery cells at a bottom portion of the support plate
Data Source
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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.