Foam-Spaced Pouch Battery Module for Uniform Cell Pressure
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Solution Overview
Problem
Existing battery modules suffer from reduced cycle life and durability due to uneven surface pressure distribution among pouch-type battery cells, leading to rapid degradation and shortened lifespan, especially under high temperature conditions.
Innovation Solution
Incorporation of a foam member and guide member to stabilize the arrangement of battery cells, reducing deviations in surface pressure and collision through the use of guide pins, strings, insulating films, or mesh sheets to maintain consistent spacing and support the cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If compression pads are used between pouch-type battery cells, then the battery cells are held and moved, but the surface pressure distribution becomes uneven leading to degradation
Solution Approach 1:
The patent changes the material parameter of the cushioning member from traditional compression pads to foam material, which provides more uniform pressure distribution. The foam member's cellular structure allows it to deform and adapt to the battery cell surfaces, maintaining consistent contact pressure across all cells during charging and discharging cycles, thereby preventing localized degradation and extending cycle life.
Solution Approach 2:
The foam member acts as an intermediary between the battery cells, providing a compliant interface that distributes forces evenly. Unlike rigid compression pads, the foam material can deform to accommodate slight variations in battery cell dimensions and positions, ensuring uniform surface pressure distribution and preventing stress concentration that would lead to cell degradation.
2Stability of the object's composition
If compression pads are compressed between battery cells, then the cells are secured, but deviation in surface pressure increases due to non-constant intervals
Solution Approach 1:
The patent changes the mechanical property parameter of the cushioning material from rigid (compression pads) to compliant (foam). The foam member's ability to deform under load allows it to compensate for variations in battery cell spacing, maintaining uniform surface pressure distribution even when intervals between cells are not perfectly constant, thus reducing pressure deviation across the battery module.
3Temperature
If battery cells are exposed to high temperature environment, then gas is generated causing swelling, but deviation of surface pressure is further increased leading to rapid degradation
Solution Approach 1:
The foam member provides beforehand cushioning by being pre-installed between battery cells with sufficient thickness and compressibility. When gas generates and cells swell due to high temperature exposure, the foam member can deform and absorb the expansion pressure, preventing excessive surface pressure concentration on individual cells. This prior cushioning capability protects cells from thermal-induced degradation and extends lifespan.
4Manufacturing precision
If guide member is added to maintain consistent spacing, then arrangement precision is improved, but device complexity increases
Solution Approach 1:
The foam member serves multiple functions simultaneously: it acts as a cushioning element for mechanical protection, a positioning element for maintaining consistent spacing between cells, and a thermal insulation layer. By integrating these functions into a single component, the patent achieves precise cell spacing without adding separate guide members or structural elements, thereby avoiding increased device complexity while improving manufacturing precision.
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 extends the lifespan of the battery module by reducing degradation and impact-induced damage, enhancing manufacturing efficiency, and minimizing weight while maintaining energy density.
Implementation Method 1
a foam member filled in at least one of between the cell frame and the plurality of battery cells and between the plurality of battery cells
Data Source
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AI summary
Provided are a battery module in which a cycle life and durability against external impact are improved and a method of manufacturing the battery module. A battery module according to the present disclosure includes a plurality of battery cells arranged in at least one direction and spaced apart from one another by a certain interval, a cell frame including a receiving space in which the plurality of battery cells are accommodated, and a foam member filled in at least one of between the cell frame and the plurality of battery cells and between the plurality of battery cells.