Battery Module Cured Sealing Insulating Layer

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Solution Overview

Problem

Existing battery modules for electric vehicles face challenges in achieving a low weight while maintaining effective cooling and stability, as they often rely on heavy metal components for sealing and structural integrity.

Innovation Solution

A battery module design featuring a trough-shaped battery box with an insulating layer formed from a cured sealing compound, which provides a fluid-tight sealing and adhesive connection, allowing for efficient cooling without compromising structural stability or weight, and includes features like retaining plates and sealing mats to manage the sealing compound and prevent coolant leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal components are used for sealing and structural integrity, then stability and strength are improved, but weight increases

Engineering Contradiction:

Improvestructural integrityVSAvoidbattery module weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the physical state of the sealing compound from liquid to solid through curing, transforming it from a fluid sealing material to a rigid structural component that provides both sealing and mechanical strength, replacing the need for heavy metal parts

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining the insulating layer (cured sealing compound), battery cells, and cooling channels into an integrated unit that achieves both lightweight construction and structural integrity, eliminating separate metal sealing components

Inventive Principle:

Principle #40Composite materials

2Reliability

If a fluid-tight sealing is implemented to prevent coolant leakage, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecoolant sealingVSAvoidsealing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the sealing function, insulation function, and structural support function into a single insulating layer made from cured sealing compound, eliminating the need for separate sealing components and reducing overall device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating layer performs multiple functions simultaneously: it provides fluid-tight sealing against coolant, electrical insulation around battery poles, and structural support for the battery module, replacing multiple specialized components

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If the insulating layer is made sufficiently thick to provide stability and strength, then strength is improved, but weight increases

Engineering Contradiction:

Improveinsulating layer strengthVSAvoidinsulating layer weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material properties of the sealing compound through curing, transforming it from a lightweight liquid to a high-strength solid that provides structural support at minimal thickness, achieving strength-to-weight optimization

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical fastening and thick structural layers with chemical bonding through curing, achieving high strength at minimal thickness and reducing overall weight

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables a stable and lightweight battery module with enhanced cooling efficiency, preventing coolant from reaching electrical poles and ensuring reliable electrical contact, while minimizing the risk of damage from loads and maintaining efficient heat transfer.

Implementation Method 1

The sealing compound may be a two-component system with a resin and a curing agent applied in a liquid state and then cured to harden for forming the insulating layer

Methodology Applied

Scientific EffectCuring:

Implementation Method 2

The sleeve can be rinsed with a coolant so that heat of the battery cell is absorbed from the sleeve and is transported away so that the battery cell can be cooled

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9406983B2Battery module

Publication Date: 2016.08.02 DR ING H C F PORSCHE AG

AI summary

A battery module (10) for the purely electric driving of a motor vehicle has a trough-shaped battery box (12) that runs around a circumferential direction, an inlet for feeding a coolant into a cooling space (30) partially bounded by the battery box (12), an outlet for conducting the coolant away from the cooling space (30), battery cells (14) in the battery box (12) and arranged in the cooling space (30), and an insulating layer (16) for fluid-tight sealing of the cooling space (30). At least one electrical pole (18) of the battery cell (14) projects out of the cooling space (30) through the insulating layer (16). The insulating layer (16) is formed from a previously liquid cured sealing compound. The insulating layer (16) can simultaneously make available a high sealing effect and a statically stabilizing effect for the battery box (12) together with a low intrinsic weight.