Thermally Conductive Battery Module Coating for Insulation and Cooling

Solution Overview

Problem

The existing battery modules face issues with deteriorated lifespan and reduced cooling efficiency due to insulation painting interfering with cooling performance, particularly when secondary batteries are connected in series for high-power applications like hybrid vehicles.

Innovation Solution

A battery module with a thermally conductive coating layer on the internal surfaces of the module case, comprising a polymeric binder resin and inorganic filler, providing a thickness of 70 μm to 130 μm, thermal conductivity of 200 W/mK to 230 W/mK, and a withstand voltage intensity of 2.5 to 4.0 kV, which enhances insulation and cooling while maintaining adhesive strength and surface roughness for improved contact area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating painting operation is performed between the battery cell and module case, then insulation performance is improved, but cooling efficiency deteriorates

Engineering Contradiction:

Improveinsulation performanceVSAvoidcooling efficiency

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent applies different coating materials to different regions of the module case. The first coating layer (insulating) is applied to areas where electrical insulation is needed, while the second coating layer (thermally conductive) is applied to areas requiring heat dissipation. This local differentiation resolves the contradiction by providing both insulation and cooling functions in appropriate locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite coating structures where multiple coating layers with different properties are applied to the module case. The combination of insulating coating material and thermally conductive coating material creates a composite system that simultaneously provides both electrical insulation and thermal conduction, resolving the contradiction between these two opposing requirements.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a thick coating layer is applied for insulation, then insulation performance is improved, but thermal conductivity deteriorates

Engineering Contradiction:

Improveinsulation performanceVSAvoidthermal conductivity

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies different coating materials to different regions of the module case. The first coating layer (insulating) is applied to areas where electrical insulation is needed, while the second coating layer (thermally conductive) is applied to areas requiring heat dissipation. This local differentiation resolves the contradiction by providing both insulation and cooling functions in appropriate locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite coating structures where multiple coating layers with different properties are applied to the module case. The combination of insulating coating material and thermally conductive coating material creates a composite system that simultaneously provides both electrical insulation and thermal conduction, resolving the contradiction between these two opposing requirements.

Inventive Principle:

Principle #40Composite materials

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 improves cooling efficiency, maintains insulation performance, and extends the lifespan of battery modules by enhancing thermal conductivity and withstand voltage, ensuring safe and efficient operation in high-power applications.

Implementation Method 1

a thermally conductive coating layer formed on an internal surface of the lower plate or an internal surface of the lower plate and an internal surface of the side plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the thermally conductive coating layer includes a polymeric binder resin and an inorganic filler

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240072329A1Battery module with improved cooling performance and method for preparing the same

Publication Date: 2024.02.29 SK ON CO LTD

AI summary

A battery module including at least one battery cell; a module case in which the at least one battery cell is accommodated, and including a lower plate and a side plate forming an internal space; and a thermally conductive coating layer formed on an internal surface of the lower plate or an internal surface of the lower plate and an internal surface of the side plate, and having a thickness of 70 μm to 130 μm, wherein the thermally conductive coating layer includes a polymeric binder resin and an inorganic filler, is disclosed.