Prismatic Battery Module Insulation for Heat-Dissipating Cell Mounting

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Solution Overview

Problem

Existing battery module designs face issues with unreliable electrical insulation and heat dissipation due to imperfections in the housing, leading to potential electrical contact and leaks, especially when subjected to thermal stress and mechanical forces.

Innovation Solution

A battery module design featuring prismatically designed battery cells with electrical insulation elements, such as heat-shrink tubing, and thermally conductive adhesives, ensuring a minimum distance and stable mechanical connection between cells and the housing, enhancing thermal resistance and electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If adhesive and thermal balancing material are arranged between battery cells and housing, then thermal contact is improved, but electrical insulation reliability deteriorates due to housing imperfections

Engineering Contradiction:

Improveheat dissipationVSAvoidelectrical insulation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The electrical insulation function is segmented from the housing structure by introducing separate insulation elements (insulating films or insulating coatings) applied directly to the battery cell bottoms. This separates the thermal contact function (performed by thermal balancing material) from the electrical insulation function, allowing each to be optimized independently without relying on housing perfection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Insulating films or insulating coatings are introduced as intermediary layers between the battery cell bottoms and the thermal balancing material/housing. These intermediaries provide reliable electrical insulation while allowing thermal contact to be maintained through the thermal balancing material, resolving the conflict between thermal performance and electrical insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If minimum distance is ensured through thermally conductive particles, then electrical insulation is improved, but heat dissipation area is reduced

Engineering Contradiction:

Improveelectrical insulationVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The solution segments the functions by applying insulating films or coatings only to specific areas (such as the bottom surfaces of battery cells) rather than creating uniform gaps throughout. This localized insulation approach maintains electrical insulation reliability while preserving maximum heat dissipation area through direct thermal contact in non-critical regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electrical insulation is applied locally where needed (at the battery cell-housing interface) through films or coatings, rather than uniformly across all surfaces. This allows critical areas to have insulation while non-critical areas maintain direct thermal contact for heat dissipation, optimizing both electrical safety and thermal performance.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If housing defects are present, then manufacturing cost is reduced, but electrical insulation reliability deteriorates

Engineering Contradiction:

Improvehousing toleranceVSAvoidelectrical insulation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Insulating films or coatings are applied to battery cell bottoms in advance, before assembly into the housing. This preliminary insulation action ensures that even if the housing has defects or variations, the electrical insulation is already in place and cannot be compromised by housing imperfections, thereby maintaining reliability while allowing manufacturing tolerances.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insulating films or coatings act as a protective cushion against potential electrical contact issues that could arise from housing defects. By providing this protective layer beforehand, the system becomes robust against manufacturing variations and housing imperfections without requiring higher precision housing manufacturing.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 provides reliable electrical insulation and efficient heat dissipation, preventing electrical contact and leaks, while maintaining a compact and stable cell stack structure.

Implementation Method 1

A thermal balancing material is arranged in the opening between the battery cell and the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

An electrical insulation element, which has an opening, is arranged on at least one bottom surface of a battery cell between the respective battery cell and the housing

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS20250350007A1Battery module

Publication Date: 2025.11.13 ROBERT BOSCH GMBH

AI summary

A battery module includes a plurality of prismatically configured battery cells (2) which together form a cell stack (4) and which are accommodated in a housing (3) of the battery module (1). An electrical insulation element (7) is arranged at least on a bottom surface (61) of a battery cell (2) between the respective battery cell (2) and the housing (3). The housing has an opening (8) and a thermal balancing material (9) is arranged in the opening (8) between the battery cell (2) and the housing (3).