Battery Module Spacer for Cooling Plate Clearance and Short-Circuit Prevention

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Solution Overview

Problem

Modern batteries face challenges in optimizing power-to-weight ratio and ensuring safety, particularly in maintaining electrical insulation between battery modules and temperature-control plates due to uneven surfaces and potential contaminants, which can lead to short circuits.

Innovation Solution

An electrically insulating spacer made of plastic is arranged between the battery module and the temperature-control plate to maintain a minimum clearance, ensuring electrical insulation and allowing for reduced use of thermally conductive paste, thereby enhancing temperature control and stability while preventing short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a thermally conductive paste is used between the battery module and temperature-control plate, then thermal connection is improved, but electrical insulation may be compromised due to uneven surfaces and particles

Engineering Contradiction:

Improvethermal connectionVSAvoidelectrical insulation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

An electrically insulating spacer is introduced as an intermediary element between the battery module and temperature-control plate. This spacer maintains a defined clearance that prevents direct contact and potential short circuits, while still allowing thermal coupling through the thermally conductive paste in the remaining contact areas. The spacer acts as a mediator that resolves the conflict between maintaining electrical insulation and achieving thermal connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a larger clearance is maintained between battery module and temperature-control plate for safety, then electrical insulation is improved, but thermal control efficiency deteriorates

Engineering Contradiction:

Improveelectrical insulationVSAvoidtemperature control efficiency

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The clearance distance between the battery module and temperature-control plate is precisely controlled within a specific range (0.5-2.0 mm) rather than being arbitrarily large. This parameter optimization ensures that the clearance is sufficient to maintain electrical insulation while small enough to allow effective thermal coupling through the thermally conductive paste, thus resolving the contradiction between safety and thermal efficiency.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If more thermally conductive paste is used to improve thermal connection, then temperature control is improved, but cost and weight increase

Engineering Contradiction:

Improvetemperature controlVSAvoidthermally conductive paste volume

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The electrically insulating spacer extracts the electrical insulation function from the thermally conductive paste, allowing the paste to focus solely on thermal conduction. This separation of functions enables the use of a smaller, more economical amount of thermally conductive paste while maintaining both electrical insulation and thermal connection effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

4Temperature

If no clearance is maintained between battery module and temperature-control plate, then thermal contact is maximized, but risk of short circuits increases due to unevenness and contaminants

Engineering Contradiction:

Improvethermal contactVSAvoidshort circuit risk

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The electrically insulating spacer provides beforehand cushioning by pre-establishing a safe clearance distance that prevents direct contact between the battery module and temperature-control plate. This protective measure is built into the design from the beginning, preventing short circuits caused by surface unevenness or contaminants before they can occur, while still allowing adequate thermal contact through the controlled clearance.

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

This arrangement enables a compact design with effective temperature control, reduced material usage, cost savings, and improved durability by ensuring a consistent clearance distance and homogeneous heat transfer, while preventing electrical bridging and maintaining safety.

Implementation Method 1

The battery modules may in this case be thermally connected to the temperature-controlling plate by means of a thermally conductive medium. A thermally conductive paste may be arranged between the battery module and temperature-control plate as thermally conductive medium.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an electrically insulating spacer is arranged between the battery module and the temperature-control plate. The arrangement of a spacer allows a minimum distance in the form of a clearance to be ensured between the battery module and the temperature-control plate, with the result that the electrical insulation between the battery module and temperature-control plate can be maintained

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS20240162523A1Battery for a motor vehicle

Publication Date: 2024.05.16 WEBASTO AG

AI summary

A for a motor vehicle, comprising a battery module and a temperature-control plate, where a thermally conductive paste is arranged between the battery module and the temperature-control plate, where an electrically insulating spacer is arranged between the battery module and the temperature-control plate.