Pouch Cell Foam Pad Structure for Uniform Swelling Pressure
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Solution Overview
Problem
Existing battery modules struggle to effectively manage cell swelling, leading to uneven pressure distribution and deformation among battery cells when swelling occurs.
Innovation Solution
A battery module design featuring a pouch case with a foam pad layer as the outermost layer, comprising inner and outer resin layers and a metal layer, which absorbs swelling and ensures uniform pressure distribution across the battery cell stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a compression pad is formed between the module frame and battery cells to manage swelling, then swelling control is improved, but the compression pad reaches a minimum compression thickness where it can no longer perform compression, making it difficult to flexibly cope with swelling
Solution Approach 1:
The patent changes the material parameter of the compression element from a conventional solid foam pad to a braid structure with inherent elasticity. This braided configuration allows the material to dynamically adjust its compression force based on swelling程度, maintaining effective compression across varying swelling conditions without reaching a minimum effective thickness.
Solution Approach 2:
The patent employs a composite structure combining the braid layer with the pouch case, creating a hybrid system that integrates the structural integrity of the pouch with the elastic compression properties of the braid. This composite approach enables both swelling control and continuous adaptability.
2Quantity of substance
If battery cells are stacked in a multi-module structure to increase capacity, then energy storage capacity is improved, but uneven pressure distribution and deformation occur among battery cells when swelling happens
Solution Approach 1:
The patent applies the braid layer locally at specific positions within the pouch case structure, allowing different regions to have differentiated functions. The braid provides localized elastic compression where needed, ensuring uniform pressure distribution across the battery cell stack while maintaining the overall multi-module high-capacity structure.
Solution Approach 2:
The braid structure introduces dynamic elasticity to the pouch case system, enabling it to automatically adjust and redistribute pressure in response to swelling. This dynamic response ensures that pressure remains evenly distributed across all battery cells in the stack, preventing deformation even as capacity increases through multi-module configuration.
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 foam pad layer effectively controls cell swelling, ensuring uniform pressure distribution and deformation across the battery cell stack, eliminating the need for separate compression pads and enhancing overall module stability.
Implementation Method 1
a foam pad layer for controlling cell swelling is located at the outermost part of the pouch case
Data Source
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AI summary
A battery module according to an embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked, and a module frame for housing the battery cell stack, wherein the battery cell comprises a pouch case and an electrode assembly housed in the pouch case, and wherein a foam pad layer for controlling cell swelling is located at the outermost part of the pouch case.