Resin-Filled Battery Module Structure for Thermal Runaway 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 cell stack arranged in a widthwise direction, using an insulating and adhesive resin to fix the cells within a frame, incorporating a resin with phase-changing and flame-retardant materials to absorb heat and prevent thermal propagation, and a resin cover to ensure uniform pressure and stable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If resin is used to fix the cell stack on the bottom plate, then heat dissipation is improved, but the resin contacts only the bottom of the cell stack resulting in insufficient heat dissipation and poor structural stability
Solution Approach 1:
The resin is applied not only on the bottom plate but also extends up the side walls of the frame, transforming a one-dimensional bottom contact into a multi-dimensional contact system that wraps around the cell stack, thereby improving both heat dissipation surface area and structural fixation
Solution Approach 2:
The resin application is divided into multiple regions: bottom plate coverage, side wall coverage, and potential inter-cell spacing, allowing each region to perform specialized functions for comprehensive heat management and structural stability
2Loss of energy
If resin is used to conduct heat from the cell stack, then thermal conductivity is improved, but the resin may melt in high temperature heat damaging structural thermal stability
Solution Approach 1:
The resin is formulated as a composite material combining thermally conductive fillers (such as aluminum oxide, aluminum nitride, or boron nitride particles) with a heat-resistant polymer matrix, enabling the material to maintain structural integrity at high temperatures while effectively conducting heat away from the cell stack
Solution Approach 2:
The resin's thermal and mechanical properties are optimized by adjusting the concentration and type of thermally conductive fillers, the polymer matrix composition, and the curing process parameters to achieve a balance between heat conduction efficiency and thermal runaway resistance
3Strength
If multiple parts including frame and end plates are used, then structural support is improved, but assembly convenience deteriorates and manufacturing complexity increases
Solution Approach 1:
The frame structure is integrated with the resin bonding system, where the resin serves dual functions as both structural adhesive and thermal management material, eliminating the need for separate end plates and simplifying the assembly process into a single bonding operation
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 provides enhanced thermal and structural stability, preventing cell movement and thermal runaway, while simplifying assembly and reducing costs through efficient resin use and integration of a bus bar system.
Implementation Method 1
the resin may include at least one of a phase changing material and a thermally conductive resin
Implementation Method 2
The resin 3 includes a thermally conductive resin having high thermal conductivity
Data Source
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AI summary
The present invention provides a structure of a battery module including: a cell stack wherein a plurality of battery cells are 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 also provides a method of manufacturing the same.