Battery Module Barrier With Flanges And Spacers For Thermal Management
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Solution Overview
Problem
High-power battery modules face challenges in electrical safety and heat management, with existing designs potentially leading to short circuits and overheating due to the close proximity of battery cells and housing, which can result in safety hazards and reduced module lifespan.
Innovation Solution
A battery module design featuring a barrier with flanges and spacers that separates battery cells and housing, using insulating materials and strategically placed openings for heat exchange, while preventing electrical connections between cells and housing, thereby enhancing safety and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are placed in close proximity to maximize energy density, then the energy density improves, but the risk of short circuits and electrical safety hazards increases
Solution Approach 1:
The patent introduces barriers with flanges and spacers as intermediary components between adjacent battery cells. These barriers include insulating materials that prevent direct electrical contact between cells while maintaining close proximity for high energy density. The flanges extend between cells and the housing, creating multiple isolation zones that eliminate short circuit risks without increasing cell spacing.
Solution Approach 2:
The barrier structure is segmented into multiple functional parts: a base portion positioned between cells, flanges extending from the base to contact both cells and housing, and spacers providing additional insulation. This segmentation allows each component to perform specific isolation functions, ensuring comprehensive electrical safety while maintaining compact cell arrangement.
2Volume of moving object
If battery cells are positioned close to the housing to reduce module size, then the module compactness improves, but heat dissipation becomes difficult leading to overheating
Solution Approach 1:
The barrier flanges act as intermediary thermal management components by creating controlled air gaps between battery cells and the housing. These gaps serve as thermal isolation zones that prevent heat buildup against the housing while allowing the compact cell arrangement to be maintained. The flanges effectively mediate between the need for compactness and heat dissipation requirements.
3Reliability
If barriers are added between battery cells to prevent short circuits, then electrical safety improves, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single barrier component: electrical insulation between cells, mechanical spacing maintenance, thermal management through air gap creation, and structural support. By combining these functions into one integrated barrier structure with flanges and spacers, the design achieves high electrical safety without proportionally increasing overall device complexity.
Solution Approach 2:
The barrier structure serves multiple purposes simultaneously: it provides electrical insulation to prevent short circuits, maintains proper cell spacing, facilitates thermal management by creating air gaps, and offers mechanical support. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving comprehensive electrical safety.
4Temperature
If spacers are used to maintain distance between battery cells and housing, then heat management improves, but manufacturing complexity increases
Solution Approach 1:
The spacer function is merged with the barrier structure itself. The flanges of the barrier extend between the battery cells and the housing, inherently providing the spacing needed for thermal management. This integration eliminates the need for separate spacer components, thereby improving heat management without significantly increasing manufacturing complexity.
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 electrical safety by preventing short circuits and effectively manages heat, extending the battery module's lifespan by maintaining optimal temperature control and isolating components to prevent electrical connections.
Implementation Method 1
The barrier may be formed of an insulating material
Implementation Method 2
strategically placed openings for heat exchange
Data Source
AI summary
A battery module including a plurality of battery cells; a housing fixing a position of the plurality of battery cells; and a barrier between adjacent ones of the plurality of battery cells, the barrier including a base facing a wide surface of the battery cells, and at least one flange on a periphery of the base, wherein the at least one flange includes at least one flange battery spacer on an inner side thereof and at least one housing spacer on an outer side thereof.