Battery Module Insulation Barrier for Creepage Distance Control
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Solution Overview
Problem
Existing battery modules have a short electrical safety distance between the battery cell housing and the side plate, leading to potential safety issues due to charge leakage along the inner wall of the side plate.
Innovation Solution
A battery module design that includes a side plate circumferentially arranged around a battery cell array with an insulation barrier protruding above the array, increasing the creepage distance by providing an insulation layer and sheet configuration between the side plate and the battery cell array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the side plate size is compressed to reduce battery module size, then the energy density is improved, but the electrical safety distance between the battery cell housing and the side plate is reduced
Solution Approach 1:
An insulation barrier comprising an insulation layer and an insulation sheet is introduced as an intermediary component between the side plate and the battery cell array. The insulation layer is disposed on the inner surface of the side plate, while the insulation sheet extends from the insulation layer toward the battery cell array, creating a multi-layer insulating structure that effectively increases the electrical safety distance without requiring an increase in side plate size.
Solution Approach 2:
The insulation sheet extends in the height direction (vertical dimension) from the insulation layer on the side plate toward the battery cell array. This dimensional extension adds insulation coverage in the vertical dimension, effectively increasing the creepage distance and electrical safety margin without expanding the horizontal footprint or side plate dimensions.
2Volume of moving object
If the side plate size is compressed to reduce battery module size, then the volume is reduced, but the charge leakage risk along the inner wall of the side plate increases
Solution Approach 1:
The insulation barrier serves as a mediating layer that physically separates the conductive side plate from the battery cell housing, preventing direct contact and the associated charge leakage pathway. The insulation layer and insulation sheet together form a comprehensive barrier that blocks electrical conduction along the inner wall of the side plate.
Solution Approach 2:
The insulation barrier utilizes thin film structures (insulation layer and insulation sheet) that provide effective electrical insulation while occupying minimal space. These thin insulating films are disposed between the side plate and battery cell array, preventing charge leakage without significantly increasing the battery module volume.
3Reliability
If an insulation barrier is added to increase creepage distance, then the electrical safety performance is improved, but the device complexity increases
Solution Approach 1:
The insulation barrier is segmented into two distinct components: an insulation layer disposed on the side plate and an insulation sheet extending from the insulation layer. This segmentation allows for simplified manufacturing and assembly, where each component can be independently prepared and then combined, reducing overall complexity compared to a monolithic insulation structure.
Solution Approach 2:
The insulation layer and insulation sheet are combined to form an integrated insulation barrier system. The insulation sheet is connected to the insulation layer, creating a unified structure that provides comprehensive insulation coverage. This merging of components achieves enhanced electrical safety while maintaining manufacturing simplicity through a modular design approach.
Data Source
AI summary
Disclosed are a battery module and an electrical device including the battery module. The battery module includes: a battery cell array, a side plate and an insulation barrier. The side plate is arranged corresponding to at least one surface on the outer side of the battery cell array in the circumferential direction; the insulation barrier is arranged between the side plate and the side wall of the battery cell array, and protrudes above the battery cell array. The battery module may overcome the problem of the existing battery module, that is, the short electrical safety distance between the housing of the battery cell and the side plate of the battery module.