Battery Module Insulator Structure for Uniform Cell Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional insulators in battery modules lead to uneven expansion of battery cells, resulting in faster attenuation near end plates, which shortens the cycle life of both the module and the battery pack.
Innovation Solution
An insulator design with protrusions and a heat insulation plate, where the heat insulation plate's height is lower than the protrusions, providing expansion spaces at both sides of the battery cell near the end plate, ensuring consistent attenuation across all cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulator is closely attached to the battery cell, then the insulation effect is improved, but the expansion space for battery cells is reduced, causing uneven attenuation and shortened cycle life
Solution Approach 1:
The insulator is divided into multiple components: an insulating plate with protrusions and a separate heat insulation plate. The protrusions create segmented expansion spaces between the heat insulation plate and battery cells, allowing differential expansion while maintaining insulation. This segmentation resolves the contradiction by providing both insulation and expansion capability.
Solution Approach 2:
The heat insulation plate is nested within the mounting portion formed by the protrusions of the insulating plate. This nested structure allows the heat insulation plate to be held in position while maintaining a controlled gap for expansion, achieving both insulation and expansion space requirements simultaneously.
2Stability of the object's composition
If the insulator is closely attached to the battery cell, then the structural stability is improved, but the expansion space near end plates is insufficient, causing faster attenuation
Solution Approach 1:
The protrusions create localized expansion spaces at specific positions (near end plates) while maintaining close attachment in other areas. The heat insulation plate is positioned at a controlled distance from battery cells only where expansion is needed, providing local quality variation that satisfies both stability and expansion requirements.
Solution Approach 2:
The solution introduces a vertical dimension through the height difference between the heat insulation plate and protrusions. This creates expansion space in the vertical direction while maintaining horizontal stability, resolving the contradiction by utilizing another spatial dimension.
3Ease of manufacture
If the heat insulation plate height is equal to protrusion height, then the manufacturing simplicity is improved, but the expansion space consistency is poor, causing uneven attenuation
Solution Approach 1:
The design specifies a parameter change: the heat insulation plate height is deliberately made less than the protrusion height. This parameter modification creates consistent expansion spaces while maintaining manufacturing feasibility through standard cutting and assembly processes, balancing manufacturing simplicity with expansion consistency.
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
Ensures consistent expansion and attenuation of battery cells, thereby extending the cycle life of both the module and the battery pack by maintaining stability during operation.
Implementation Method 1
a heat insulation plate provided in the mounting portion
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An insulator and a battery module are provided in the application. The insulator includes: an insulating plate including a body and protrusions, wherein the protrusions are provided at two ends of at least one side surface of the body, and a mounting portion is formed between the protrusions at the at least one side surface of the body ; and a heat insulation plate provided in the mounting portion, wherein a height of a side of the heat insulation plate away from the body is lower than heights of sides of the protrusions away from the body.