Resin-Filled Battery Module Structure for Thermal Stability
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Solution Overview
Problem
Existing battery modules suffer from inadequate heat dissipation, structural instability, and risk of thermal runaway due to insufficient resin contact and movement of battery cells, leading to potential ignition and assembly complexity.
Innovation Solution
A battery module structure with a frame and insulating resin that adheres to battery cells, incorporating a mount member and resin cover to fix and insulate cells, using materials like silicone and aluminum hydroxide for improved stability and heat absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If resin is used to fix battery cells to the frame, then heat dissipation is improved, but the resin may melt in high temperature and damage structural thermal stability
Solution Approach 1:
The patent uses a composite material consisting of intumescent resin and aluminum hydroxide powder. The intumescent resin provides adhesive and insulating properties, while the aluminum hydroxide powder (60-80 wt%) acts as a flame retardant that decomposes at high temperatures to release water vapor, forming a protective char layer that prevents thermal propagation and maintains structural stability during thermal runaway events.
2Ease of manufacture
If resin is applied only to the bottom of the cell stack, then assembly is simplified, but heat dissipation is insufficient and cells may move without being fixed
Solution Approach 1:
The patent segments the resin application into multiple locations: the bottom surface of the frame, the side surfaces of the battery cells, and the spaces between adjacent cells. This multi-point application ensures comprehensive heat dissipation pathways while firmly fixing the cells to prevent movement, all within a single assembly process.
3Stability of the object's composition
If multiple parts including frame and end plates are used, then structural stability is improved, but durability is reduced and assembly becomes inconvenient
Solution Approach 1:
The patent merges multiple structural components into a single integrated frame structure. The frame includes a bottom surface with resin application areas and side surfaces that directly contact and secure the battery cells. This integration eliminates the need for separate end plates and multiple assembly steps, reducing the number of parts while maintaining structural stability through the resin-based fixation system.
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
Enhances thermal and structural stability by preventing cell movement, blocking thermal propagation, and ensuring uniform heat dissipation, while simplifying assembly and reducing costs.
Implementation Method 1
a resin having an insulating property and filling at least a portion of a space between the plurality of battery cells and the frame
Implementation Method 2
The resin 3 includes a thermally conductive resin having high thermal conductivity
Implementation Method 3
using materials like silicone and aluminum hydroxide for improved stability and heat absorption
Data Source
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AI summary
The present invention provides: a structure of a battery module comprising: a plurality of battery cells stacked in widthwise direction, each of the plurality of battery cells having a pair of electrode leads protruding in upward direction; a frame having an open upper portion and accommodating the cell stack; and a resin having an insulating property and filling at least a portion of a space between the cell stack and the frame; and a method of manufacturing the same.