Battery Module with Conductive Intermediate Walls
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Solution Overview
Problem
Existing battery modules face challenges in weight reduction, cost minimization, and efficient thermal management while maintaining electrical connectivity and gas-tight sealing, particularly in high-energy density applications like electric vehicles.
Innovation Solution
A battery module design featuring a housing made of electrically insulating polymer material with intermediate walls of conducting metal, allowing series electrical connection of electrode assemblies and integrating a cooling plate for thermal management, while being flexible to accommodate various electrode types and preventing electrolyte diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a common housing is shared among multiple electrode assemblies, then weight and cost are reduced, but manufacturing complexity increases
Solution Approach 1:
The housing is segmented into a base body and a cover that can be separately manufactured and then assembled. The base body contains integrated intermediate walls that divide the housing into multiple compartments for electrode assemblies. This segmentation allows each part to be manufactured independently using injection molding, reducing overall manufacturing complexity while achieving weight reduction through the common housing structure.
Solution Approach 2:
The intermediate walls are merged directly into the base body of the housing as integral structures during injection molding, rather than being separate components. The conductive barriers are also integrated into the housing material. This merging reduces the number of parts and assembly steps, simplifying manufacturing while maintaining the weight benefits of a unified housing structure.
2Reliability
If intermediate walls are made of electrically conducting material for series connection, then electrical connectivity is improved, but thermal management becomes more challenging
Solution Approach 1:
The intermediate walls are constructed as composite structures with outer layers of electrically conducting material (such as aluminum or stainless steel) for series electrical connection, and an inner core of thermally conductive material for heat dissipation. This composite design simultaneously achieves both electrical connectivity and thermal management functions within the same component.
Solution Approach 2:
The intermediate walls serve multiple functions: they provide electrical connection between adjacent electrode assemblies in series, act as structural separators between compartments, and function as thermal conduction paths to transfer heat from the electrodes to the cooling plate. This multi-functionality resolves the contradiction by integrating both electrical and thermal management capabilities into a single component.
3Reliability
If the housing is made of electrically insulating material for safety, then electrical safety is improved, but thermal conductivity decreases
Solution Approach 1:
The intermediate walls made of electrically conducting material act as intermediaries between the electrically insulating housing and the electrode assemblies. They provide the necessary electrical connection while the insulating housing material maintains electrical safety. The thermal conduction path is established through the conducting intermediate walls rather than through the housing material itself, thus resolving the contradiction between electrical insulation and thermal conductivity.
4Reliability
If intermediate walls are inserted into the housing material for sealing, then gas-tightness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The intermediate walls are pre-formed as separate components with precise dimensions and insertion features before being integrated into the housing. The base body is designed with pre-formed receptacles or channels that guide the intermediate walls into their final positions during assembly. This preliminary preparation of components and fixtures reduces the precision requirements during the actual insertion process while ensuring gas-tight sealing.
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 reduces weight and cost by sharing a common housing among multiple electrode assemblies, enhances thermal conductivity, and ensures gas-tight compartments, improving the module's performance and reliability in electric vehicles.
Implementation Method 1
The intermediate walls are made of least one electrically conducting material, in particular metal... enhances thermal conductivity
Implementation Method 2
ensures gas-tight compartments, preventing electrolyte diffusion
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention refers to a battery module (2), comprising a housing (20) with several compartments (45), intermediate walls (30) separating adjacent compartments (45) and electrode assemblies (10) arranged in the compartments (45). The intermediate walls (30) are made of least one electrically conducting material and electrodes (11) of the electrode assemblies (10) are electrically connected to the intermediate walls (30).