Battery Module Insulation Openings for Heat Dissipation and Bonding
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Solution Overview
Problem
Existing battery modules suffer from poor heat dissipation due to excessive thickness and repeated coverage areas caused by circular wrapping methods and glue layers, leading to potential short circuits and reduced capacity.
Innovation Solution
A battery module design featuring an insulating layer with openings and a structural adhesive, where the insulating layer thickness is reduced in the openings, allowing for direct connection without overlapping structures, enhancing bonding stability and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circular wrapping method is used to wrap the battery with an insulating layer, then the insulating coverage is improved, but the repeated coverage area on the bottom or side of the battery increases, resulting in excessive local thickness
Solution Approach 1:
The insulating layer is segmented into different thickness zones: a first insulating layer with greater thickness and a second insulating layer with smaller thickness. This segmentation allows the battery to have sufficient insulation coverage while reducing the repeated coverage area and local thickness through the offset arrangement of the two layers.
Solution Approach 2:
Different parts of the insulating layer have different thicknesses to meet different functional requirements. The first insulating layer provides thicker insulation where needed, while the second insulating layer provides thinner coverage in areas where repeated wrapping occurs, optimizing both insulation performance and heat dissipation.
2Ease of manufacture
If a glue layer is added to facilitate connection between batteries, then the ease of assembly is improved, but the heat dissipation effect of the battery module deteriorates
Solution Approach 1:
The adhesive layer is extracted from the connection structure and replaced by direct contact between the second insulating layers of adjacent batteries. This eliminates the adhesive layer that hindered heat dissipation while maintaining the ease of assembly through the self-aligning offset arrangement of the insulating layers.
Solution Approach 2:
The second insulating layer acts as an intermediary that enables both connection and heat dissipation. Instead of using adhesive as the mediator for connection, the insulating layer itself serves as the connecting element through its offset arrangement, allowing direct thermal contact between batteries while maintaining structural integrity.
3Strength
If multiple layers of insulating material and glue layers are used to connect batteries, then the bonding strength is improved, but the local thickness becomes too thick, causing heat concentration
Solution Approach 1:
The insulating function and connection function are merged into a single integrated structure. The second insulating layers of adjacent batteries directly contact each other in an offset arrangement, simultaneously providing insulation, connection, and heat dissipation pathways, eliminating the need for separate adhesive layers.
4Reliability
If an insulating layer is provided to prevent short circuits between adjacent batteries, then the safety is improved, but the structural complexity increases due to extra layers
Solution Approach 1:
The insulating layer is designed to perform multiple functions simultaneously: electrical insulation to prevent short circuits, mechanical connection between batteries, and thermal management through its offset arrangement. This multi-functionality reduces the need for separate components and simplifies the overall structure.
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 design improves heat dissipation efficiency, reduces local thickness, and increases capacity by avoiding extra layers, thereby preventing short circuits and optimizing structural integrity.
Implementation Method 1
a structural adhesive, arranged on a surface of the battery cell, and located in the opening, and each battery and adjacent components to the battery are connected by the structural adhesive
Implementation Method 2
a thickness of the insulating layer in the opening being smaller than a thickness of other parts of the insulating layer... improve the heat dissipation efficiency
Data Source
AI summary
This application provides a battery and a battery module. The battery module includes a plurality of batteries and a structural adhesive. Each battery includes a battery cell and an insulating layer. The insulating layer is arranged on a side of the battery cell. One or more openings are formed in the insulating layer. The insulating layer in the one or more openings is less in thickness than other parts of the insulating layer. The structural adhesive is arranged on a surface of the battery cell, and is located in at least one of the one or more openings, and the battery and a component adjacent to battery are connected by the structural adhesive.