Battery Module Conductive Sheet Plastic Insulation Layer

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Solution Overview

Problem

In battery modules, electrolyte leakage from defective cells can cause temperature rises in conductive sheets and other cells due to thermal conduction, leading to potential damage.

Innovation Solution

A battery module design featuring a plastic protective layer on the outer surface of conductive sheets and protection units, applied via injection molding, to minimize contact between leaked electrolyte and these components, and a protection unit that disconnects when temperature or current exceeds presets to prevent further damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conductive sheets are used to connect battery cells, then electrical conductivity is improved, but thermal conduction from leaked electrolyte causes temperature rise and potential damage

Engineering Contradiction:

Improveelectrical conductivityVSAvoidtemperature rise from thermal conduction

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A plastic protective layer is introduced as an intermediary between the conductive sheet and the leaked electrolyte. This layer has low thermal conductivity to block heat transfer while maintaining electrical conductivity of the underlying conductive sheet for normal operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

A thin plastic protective layer is applied on the conductive sheet to provide thermal insulation. The thin film structure maintains flexibility and electrical conductivity while blocking thermal conduction from electrolyte leakage.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If protection units are added to disconnect defective cells, then safety is improved, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protection unit is designed to automatically detect temperature or current anomalies and disconnect defective battery cells without external intervention. This self-service mechanism enhances safety while minimizing the need for complex external control systems.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The protection unit monitors parameters such as temperature and current, and automatically changes the electrical state from connected to disconnected when thresholds are exceeded. This parameter-based control provides simple yet effective safety protection.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If plastic protective layer is applied on conductive sheet, then thermal insulation is improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvethermal conduction protectionVSAvoidmanufacturing process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The plastic protective layer and conductive sheet are combined into a single integrated component through injection molding. This merging of functions reduces the number of separate manufacturing steps and assembly operations required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic protective layer serves multiple functions: thermal insulation, physical protection, and structural support. This multi-functionality reduces the need for additional separate components and simplifies the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution effectively reduces the risk of temperature increases and damage to normal cells by limiting electrolyte contact and automatically disconnecting faulty cells, enhancing the safety and reliability of the battery module.

Implementation Method 1

The plastic protective layer is provided by injection molding on partial surface of the conductive sheet to avoid contact between the high temperature electrolyte and the conductive sheet, thereby causing rise in temperature of the conductive sheet and other normal battery cells

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The conductive sheet receives heat from the electrolyte by thermal conduction, which may cause rias in the temperature of the conductive sheet and the connected battery cells

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11189893B2Battery module

Publication Date: 2021.11.30 STL TECH CO LTD

AI summary

The present invention provides a battery module, including a plurality of battery cells, a plurality of conductive sheets, and at least one plastic protective layer, wherein each conductive sheet is connected in series or in parallel with a plurality of battery cells. The plastic protective layer is formed on the partial surface of the conductive sheet by injection molding to prevent the electrolyte leaked from the defective battery cell from contacting the conductive sheet, causing rise in temperature of the battery cell and causes melt or explosion of the battery cell, which is helpful to improve the safety of the battery module.