Battery Module Barriers With Composite Insulation And Mechanical Ribs
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Solution Overview
Problem
Conventional battery modules with metallic barriers lack adequate electrical insulation and mechanical strength, which can lead to inefficiencies and safety issues in high-power applications like hybrid and electric vehicles.
Innovation Solution
A battery module design featuring barriers made of non-electroconductive plastic or metallic materials with a body unit, side units, and fixing units that include through holes and connecting bars to enhance insulation and mechanical stability, allowing for improved alignment and assembly of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metallic barriers are used between battery cells, then mechanical strength is provided, but electrical insulation property is inadequate
Solution Approach 1:
The barrier uses a composite structure combining non-conductive plastic material with embedded metallic reinforcing ribs. The plastic matrix provides electrical insulation while the metallic ribs provide mechanical strength, resolving the contradiction between insulation and strength requirements.
Solution Approach 2:
The barrier has non-uniform structure with metallic reinforcing ribs strategically positioned at specific locations (such as at corners or along edges) where mechanical strength is most needed, while the majority of the barrier surface remains as non-conductive plastic to ensure electrical insulation. This local differentiation resolves the contradiction between insulation and strength.
2Reliability
If barriers are added between battery cells for insulation and strength, then safety is improved, but device complexity increases
Solution Approach 1:
The barrier structure serves multiple functions simultaneously: electrical insulation between cells, mechanical strength reinforcement, thermal management (with heat dissipation fins), and structural alignment (with positioning protrusions). By integrating these multiple functions into a single component, safety is improved without proportionally increasing complexity.
Solution Approach 2:
The barrier merges several previously separate components into one integrated structure: the insulating barrier, reinforcing elements, heat dissipation features, and positioning mechanisms are combined into a single barrier component, reducing assembly complexity while maintaining safety benefits.
3Stability of the object's composition
If fixed barrier structures are used for mechanical stability, then structural integrity is improved, but assembly efficiency decreases
Solution Approach 1:
The barrier is designed as a modular component that can be independently manufactured and then quickly assembled into the battery pack. The segmentation of the barrier into discrete, pre-fabricated units with standardized connection features enables rapid assembly while maintaining structural integrity through precise joining mechanisms.
Solution Approach 2:
The barrier includes pre-formed positioning features, alignment protrusions, and connection interfaces that are manufactured in advance. These preliminary preparations enable quick and accurate assembly without requiring complex alignment procedures or additional fastening steps during assembly, thus improving assembly efficiency while maintaining structural integrity.
Data Source
AI summary
A battery module including a plurality of battery cells arranged in a direction, and a plurality of barriers, each arranged between battery cells of the plurality of battery cells and including a body unit having at least one opening and facing a face of a battery cell of the battery cells, at least one side unit connected to at least one end of the body unit such that at least a portion of the at least one side unit contacts a side of the battery cell, and at least one fixing unit on the side unit and configured to connect the barrier to an adjacent barrier of the plurality of barriers.