Battery Module Insulation Layer for Faster Heat Transfer Assembly

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Solution Overview

Problem

Conventional battery modules suffer from low heat transfer efficiency due to insulation and adhesive layers between battery cells and heat sinks, leading to increased manufacturing costs and reduced process efficiency.

Innovation Solution

A battery module design with a tightly contacted insulation layer on the heat sink, formed using a 3D printer, eliminates the need for separate adhesive members, allowing for improved heat transfer and reduced material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive layers are used to fix the insulation layer to the heat sink and battery cells, then the insulation layer is securely fixed, but heat transfer efficiency is reduced and manufacturing cost is increased

Engineering Contradiction:

Improvefixing reliabilityVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent removes the adhesive layer from the system by designing the insulation layer with a self-adhesive surface that directly bonds to the heat sink and battery cells through surface adhesion forces, eliminating the need for separate adhesive layers while maintaining secure fixation and preserving heat transfer efficiency

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulation layer itself acts as an intermediary with dual functionality: it provides electrical insulation while its surface properties enable direct adhesion to both the heat sink and battery cells, replacing the traditional adhesive layer mediator

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If adhesive layers are used to fix the insulation layer to the heat sink and battery cells, then the insulation layer is securely fixed, but manufacturing cost is increased

Engineering Contradiction:

Improvefixing reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates the adhesive layer component and its associated procurement, storage, and application processes, reducing manufacturing cost while maintaining secure fixation through the self-adhesive properties of the insulation layer surface

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the insulation function and adhesion function into a single integrated component (the insulation layer with self-adhesive surface), eliminating the need for separate adhesive layers and simplifying the manufacturing process

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If adhesive layers are used to fix the insulation layer to the heat sink and battery cells, then the insulation layer is securely fixed, but manufacturing process efficiency is reduced

Engineering Contradiction:

Improvefixing reliabilityVSAvoidmanufacturing process efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent removes the adhesive layer application steps from the manufacturing process, eliminating the need for precise adhesive application, positioning, and curing operations, thereby significantly improving manufacturing process efficiency while maintaining secure fixation

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulation layer is pre-designed with self-adhesive surface properties during manufacturing, so that when it is placed between the heat sink and battery cells, it automatically bonds without requiring additional adhesive application steps during assembly

Inventive Principle:

Principle #10Preliminary action

4Reliability

If insulation layer and adhesive layers are provided between battery cells and heat sink, then electrical insulation is maintained, but heat transfer efficiency is low

Engineering Contradiction:

Improveelectrical insulationVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies different surface properties to different regions of the insulation layer: the surfaces contacting the heat sink and battery cells have high adhesion and thermal conductivity for efficient heat transfer and secure bonding, while the bulk material maintains electrical insulation properties

Inventive Principle:

Principle #3Local quality

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 cooling performance by rapid heat transfer and simplifies manufacturing with reduced adhesive use, lowering costs and improving process efficiency.

Implementation Method 1

heat transfer efficiency is low

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4203145B1Battery module with improved cooling performance and manufacturing method thereof

Publication Date: 2026.02.11 LG ENERGY SOLUTION LTD

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AI summary

The present invention relates to a battery module with improved cooling performance and a method of manufacturing the same, and more particularly to a battery module with improved cooling performance, the battery module including a plurality of cylindrical battery cells (200), a module frame (600) configured to electrically connect the cylindrical battery cells (200) to each other, a heat sink (300) located under the cylindrical battery cells (200), and an insulation layer (400) formed on the upper surface of the heat sink (300) in tight contact with the heat sink and a method of manufacturing the same.