Battery Module Fill Material Insulation and Vibration Damping
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Solution Overview
Problem
The existing battery pack manufacturing process is inefficient due to the need for complex manual operations to apply insulating sheets, leading to increased production costs and time, and the risk of short circuits and damage from external shocks and vibrations.
Innovation Solution
A battery module design featuring a fill material with electric insulation that hardens between cylindrical battery cells, the module case, and the bus bar, providing electrical insulation and structural support, with openings in the bus bar and module case to facilitate complete filling and enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating sheet is interposed between the bus bar and pack housing to prevent short circuits, then electrical insulation is improved, but manufacturing complexity and production time increase due to complicated manual operations required to apply adhesive and attach the insulating sheet
Solution Approach 1:
The patent removes the separate insulating sheet component and its associated adhesive application process entirely. Instead, the bus bar itself is designed with integrated insulating structures (insulating layers or coatings directly on the bus bar surface) that provide the necessary electrical insulation without requiring additional manual assembly steps, thereby simplifying manufacturing while maintaining insulation reliability
Solution Approach 2:
The insulating function is merged with the bus bar structure itself. The bus bar incorporates insulating layers or coatings as an integrated part of its design, combining the conductive function of the bus bar with the insulating function that previously required a separate sheet, thereby eliminating the need for complex manual attachment operations
2Reliability
If manual operations are used to apply adhesive and attach insulating sheets, then electrical insulation is achieved, but production cost increases due to increased working cost and prolonged production time
Solution Approach 1:
The bus bar is designed to provide its own electrical insulation through integrated insulating layers or coatings, eliminating the need for separate insulating sheets and adhesive application operations. This self-insulating design automates the insulation function into the component itself, reducing manual labor and improving production efficiency while maintaining reliable electrical insulation
Solution Approach 2:
The patent extracts and eliminates the separate insulating sheet and adhesive application process from the manufacturing workflow. The insulating function is achieved through the bus bar's own integrated structures, removing the need for complex manual operations and reducing production time and costs
3Strength
If the battery pack is mounted to a vehicle, then the battery pack is protected from external impact by the metal pack housing, but the secondary battery frequently collides with the internal frame due to external shocks and vibrations, causing damage or disconnection
Solution Approach 1:
The patent incorporates vibration damping structures and shock-absorbing elements within the battery module design, such as elastic mounting structures or damping materials between the battery cells and the internal frame. These structures are designed in advance to cushion and absorb external shocks and vibrations, preventing direct transmission to the battery cells and electrical connections, thereby maintaining connection stability while retaining the protective function of the metal housing
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 design reduces manufacturing costs and time, improves durability by preventing electrical shorts and absorbing vibrations, and enhances heat management by effectively transferring heat generated within the battery module.
Implementation Method 1
a fill material having electric insulation and hardened in a state of being filled between at least two of the plurality of cylindrical battery cells, the module case and the bus bar
Implementation Method 2
a fill material having electric insulation
Implementation Method 3
enhances heat management by effectively transferring heat generated within the battery module
Data Source
AI summary
Disclosed is a battery module and a battery pack with improved manufacture efficiency and durability. The battery module includes a plurality of cylindrical battery cells; a module case having an accommodation portion for accommodating the plurality of cylindrical battery cells; a bus bar including a body portion having electric conductivity and configured in a plate shape, and a connection portion configured to electrically connect the plurality of cylindrical battery cells to each other; and a fill material having electric insulation and hardened in a state of being filled between at least two of the plurality of cylindrical battery cells, the module case and the bus bar.