Battery Module Cooling Fin Insulation Against Housing Short Circuits
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Solution Overview
Problem
Conventional battery modules face failures due to direct contact between cooling fins and the housing, leading to short circuits caused by swelling or external impacts, which compromises insulation performance.
Innovation Solution
Incorporating an insulating cap coupled to the cooling fin's end portion, which protrudes towards the housing, to prevent direct contact and ensure insulation, along with a heat dissipating resin for enhanced cooling efficiency and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling fin protrudes toward the housing to efficiently transfer heat, then heat dissipation performance is improved, but the risk of direct contact with the housing causing short circuit increases
Solution Approach 1:
An insulating cap is introduced as an intermediary component between the cooling fin and the housing. This cap allows the cooling fin to maintain its protruding position for efficient heat transfer while preventing direct contact with the housing, thus eliminating the short circuit risk. The insulating cap mediates between the thermal management requirement and the electrical insulation requirement.
Solution Approach 2:
The cooling fin structure is transformed into a composite structure by combining the metal cooling fin with an insulating cap made of non-conductive material. This composite structure retains the high thermal conductivity of the metal fin for heat dissipation while adding electrical insulation properties through the cap, thereby simultaneously achieving both heat transfer efficiency and insulation performance.
2Quantity of substance
If battery cells are densely packed in narrow space to increase energy density, then productivity and energy density are improved, but heat dissipation becomes more difficult
Solution Approach 1:
The cooling fin extends in the width direction (perpendicular to the stacking direction of battery cells) rather than only in the stacking direction. This dimensional change allows the cooling fin to reach across multiple battery cells and make contact with the housing at a different spatial location, creating an additional heat transfer pathway that does not compromise the dense packing arrangement.
Solution Approach 2:
The cooling system is segmented into multiple cooling fins distributed among the battery cells. Each cooling fin independently contacts adjacent battery cells and transfers heat to the housing, creating multiple distributed heat dissipation channels that work simultaneously, thereby achieving effective heat management in the densely packed configuration.
3Temperature
If the cooling fin is made of metal with high thermal conductivity for efficient heat transfer, then heat dissipation performance is improved, but the risk of short circuit upon contact with housing increases
Solution Approach 1:
The cooling fin structure is transformed into a composite structure by combining the metal cooling fin with an insulating cap made of non-conductive material. This composite structure retains the high thermal conductivity of the metal fin for heat dissipation while adding electrical insulation properties through the cap, thereby simultaneously achieving both heat transfer efficiency and insulation performance.
Solution Approach 2:
Different parts of the cooling fin structure have different material properties: the fin body is made of metal for high thermal conductivity, while the cap is made of insulating material for electrical isolation. This local differentiation of material quality allows each part to fulfill its specific function - heat transfer where needed and insulation where required.
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 insulating cap effectively prevents short circuits and ensures improved insulation performance, even under abnormal conditions, thereby enhancing the reliability of battery modules and packs used in vehicles.
Implementation Method 1
The cooling fin transfers heat generated in the battery cell to a cooling medium
Implementation Method 2
an insulating cap for preventing direct contact between the at least one cooling fin and the housing
Data Source
AI summary
A battery module including a plurality of battery cells, a housing in which the plurality of battery cells are accommodated, at least one cooling fin located between the plurality of battery cells in the housing, and an insulating cap for preventing direct contact between the at least one cooling fin and the housing.