Prismatic Battery Module Insulation for Heat-Conductive Cell Stacking
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Solution Overview
Problem
Existing battery modules face issues with unreliable electrical insulation due to imperfections in the housing, leading to potential electrical contact between battery cells and the housing, which can cause leaks and failure, especially under high thermal stress.
Innovation Solution
A battery module design featuring prismatically formed battery cells with electrical insulation elements, such as shrink tubing, arranged on lateral surfaces and between cells and the housing, ensuring a minimum distance and using thermally conductive adhesives to maintain insulation and facilitate heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If adhesive and thermal compensation material are arranged between battery cells and housing, then thermal connection is improved, but electrical insulation reliability deteriorates due to housing imperfections
Solution Approach 1:
The solution segments the functional requirements by introducing a distinct electrical insulation element separate from the thermal compensation material. The insulation element is arranged between the battery cell and housing, while thermal compensation material is placed between the insulation element and housing, dividing the single interface into multiple functional layers that independently address insulation and thermal management.
Solution Approach 2:
The electrical insulation element acts as an intermediary component between the battery cell and housing, preventing direct contact and potential electrical shorts caused by housing imperfections. This intermediary layer ensures reliable electrical insulation while allowing thermal management functions to be performed by dedicated thermal compensation materials arranged in subsequent layers.
2Reliability
If minimum distance is ensured between battery cell and housing, then electrical insulation is improved, but cooling surface area is reduced
Solution Approach 1:
The solution segments the interface structure into multiple functional layers: an electrical insulation element providing minimum distance for electrical isolation, and thermal compensation material arranged between the insulation element and housing for thermal management. This segmentation allows the cooling surface area to be maintained by the thermal compensation material while the insulation element provides the necessary electrical isolation distance.
Solution Approach 2:
The solution addresses the spatial conflict by organizing components in multiple dimensional layers at the battery cell-housing interface. The electrical insulation element provides distance in the radial dimension, while thermal compensation material compensates for the reduced cooling surface area through thermal conduction in the axial dimension, effectively decoupling the two requirements.
3Volume of moving object
If battery cells are arranged closely for compact design, then space utilization is improved, but electrical insulation reliability deteriorates due to housing defects
Solution Approach 1:
The solution segments the interface into functional layers with an electrical insulation element providing reliable insulation between battery cells and housing. This allows battery cells to be arranged closely for compact design while the insulation element maintains electrical isolation even when housing imperfections or tolerances reduce the effective distance.
4Strength
If high surface pressure is applied during assembly, then mechanical connection is improved, but minimum distance for electrical insulation is compromised
Solution Approach 1:
The solution segments the interface structure into an electrical insulation element and thermal compensation material layers. The insulation element maintains the minimum distance for electrical insulation even under high assembly pressures, while the thermal compensation material ensures thermal connection. This layered segmentation allows mechanical connection strength to be improved through pressure application without compromising the electrical insulation distance provided by the insulation element.
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 reliable electrical insulation and efficient heat management, preventing electrical contact and leaks while allowing for compact and stable cell stacking, even under high thermal stress.
Implementation Method 1
the electrical insulation element is arranged between the respective battery cell and the housing, as well as between the respective battery cell and the battery cells adjacent to the battery cell
Implementation Method 2
A thermal compensation material is arranged between the battery cell and the housing
Implementation Method 3
electrical insulation elements, such as shrink tubing, arranged on lateral surfaces
Data Source
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 on a battery cell (2) at least on a bottom surface (61) of the battery cell (2) and partially on opposite lateral surfaces (62) of the battery cell (2) in such a way that the electrical insulation element (7) is arranged between the respective battery cell (2) and the housing (3), as well as between the respective battery cell (2) and battery cells (26) adjacent to the battery cell (2). A thermal compensation material (9) is arranged between the battery cell (2) and the housing (3).