Battery Module Case Layer Stack for Corona-Free Heat Radiation
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Solution Overview
Problem
Existing battery modules face challenges in effectively suppressing corona discharge in the air layer between the battery group and the metal body without increasing manufacturing complexity, while also requiring improved heat radiation and electrical insulation.
Innovation Solution
A battery module design incorporating an insulating layer and a conductive layer stacked on the metal body, with the insulating layer electrically insulating the battery group from the metal body and the conductive layer electrically connected to the battery group, eliminating air gaps and preventing corona discharge through integral formation on a metal base substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating material is provided between the battery group and the metal body to electrically insulate them, then electrical insulation is achieved, but corona discharge generation in the air layer cannot be effectively suppressed and manufacturing complexity increases
Solution Approach 1:
The insulating layer and conductive layer are merged into a single integral structure formed directly on the metal body. This combined structure simultaneously provides electrical insulation (through the insulating layer) and corona discharge suppression (through the conductive layer connected to the battery group), eliminating the need for separate insulating materials and reducing manufacturing complexity.
Solution Approach 2:
The invention uses a composite structure consisting of an insulating layer and a conductive layer formed on the metal body. This composite material approach allows the structure to exhibit both insulating properties (from the insulating layer) and conductive properties (from the conductive layer), achieving multiple functions simultaneously while simplifying the overall design.
2Temperature
If a metal body is provided to radiate heat from the battery group, then heat radiation is improved, but corona discharge occurs in the air layer between the battery group and the metal body
Solution Approach 1:
The conductive layer acts as an intermediary between the battery group and the metal body. It is electrically connected to the battery group while being in direct contact with the metal body, providing a controlled electrical path that prevents uncontrolled corona discharge in the air layer while maintaining effective thermal contact for heat radiation.
Solution Approach 2:
The invention changes the electrical parameter distribution by introducing a conductive layer with specific electrical properties between the battery group and the metal body. This modifies the electric field distribution in the air layer, preventing corona discharge while maintaining the thermal conduction path for effective heat radiation.
3Object-affected harmful factors
If additional insulating materials are used to suppress corona discharge, then corona discharge is suppressed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The insulating layer and conductive layer are formed preliminarily on the metal body before the battery group is assembled. This preliminary formation of the multi-functional layer eliminates the need for additional insulating materials during assembly and simplifies the manufacturing process, improving productivity while effectively suppressing corona discharge.
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
This design effectively suppresses corona discharge and enhances heat radiation by eliminating air layers, simplifying the manufacturing process and ensuring electrical insulation without the need for additional insulating materials, thus improving the overall performance and efficiency of the battery module.
Implementation Method 1
a metal body is provided in a case so as to radiate heat from the metal body to the outside of the battery module
Implementation Method 2
the insulating layer is stacked on a surface of the metal body on a side where the battery group is located, and has electric insulating properties
Implementation Method 3
it is necessary to effectively suppress generation of corona discharge in an air layer present between the battery group and the metal body
Data Source
AI summary
In an embodiment, a battery module includes a battery group, an electric path, a case, an insulating layer and a conductive layer. The battery group includes a plurality of batteries, and a current passes through the electric path during each of charging and discharging the plurality of batteries. The battery group is accommodated in the case, and the case includes a metal body having electric conductive properties. The insulating layer is stacked on a surface of the metal body on a side where the battery group is located, and has electric insulating properties. The conductive layer is stacked on a surface of the insulating layer on a side where the battery group is located, and is electrically connected to any of the electric path and a portion having electric conductive properties in the battery group.