Battery Module Thermal Transfer Fins with Insulating Mediator
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Solution Overview
Problem
Existing battery module technologies face challenges in efficiently regulating battery cell temperature, leading to reduced operational life and increased risk of deformation, which can result in uncontrolled discharges and safety issues.
Innovation Solution
A battery module design featuring a metal profile with thermal transfer fins and a combination of heat-conducting and electrically insulating materials to improve thermal transfer between battery cells and the metal profile, exerting pressure on cells to enhance contact and reduce mechanical stress, thereby improving temperature control and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal transfer fins are used to conduct heat away from battery cells, then temperature regulation is improved, but electrical short-circuit risk increases due to thermal contact between conducting fins and cells
Solution Approach 1:
An electrically insulating material is introduced as an intermediary layer between the thermal transfer fins and the battery cells. This mediator allows thermal energy to be conducted away from the cells while simultaneously providing electrical insulation to prevent short-circuits. The insulating material thus resolves the contradiction by enabling both heat transfer and electrical safety.
Solution Approach 2:
The solution employs composite material structure combining thermal transfer fins (heat conduction function) with electrically insulating material layers (electrical isolation function). This composite approach allows the system to simultaneously achieve effective temperature regulation and electrical safety, resolving the contradiction between thermal management and electrical reliability.
2Stability of the object's composition
If battery cells are tightly secured in the metal profile, then mechanical stability is improved, but deformation risk increases due to mechanical stress on cells
Solution Approach 1:
An electrically insulating material layer is introduced as a mechanical intermediary between the metal profile and the battery cells. This layer provides cushioning that reduces direct mechanical stress and deformation risk while still maintaining secure positioning and thermal contact. The mediator thus enables both mechanical stability and cell protection.
3Loss of energy
If thermal contact between fins and cells is maximized, then heat transfer efficiency is improved, but manufacturing precision requirements increase due to contact pressure needs
Solution Approach 1:
The introduction of the electrically insulating material layer changes the contact interface parameters, allowing for more uniform pressure distribution across the battery cell surfaces. This parameter change enables effective thermal contact without requiring extremely high manufacturing precision, as the compliant insulating layer accommodates variations and ensures consistent thermal coupling.
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 enhances temperature regulation dynamics, extends battery life, increases the number of recharge/discharge cycles, reduces deformation risk, and allows for faster charging and discharging while maintaining optimal temperatures, with a simplified construction that reduces costs and manufacturing complexity.
Implementation Method 1
heat-conducting filler material positioned between the thermal transfer fins and the battery cells for improving thermal transfer between the battery cells and the thermal transfer fins
Implementation Method 2
electrically insulating material positioned between the thermal transfer fins and the battery cells
Implementation Method 3
thermal transfer fins arranged at a space from each other... thermal energy is conducted through said aluminum or aluminum alloy profile from/to the battery cells
Data Source
Figure 1A~2
Figure 3A~3D
Figure 4A~4D
AI summary
A battery module (1) comprising a metal profile (2), the metal profile (2) being provided with a plurality of thermal transfer fins (3) arranged at a space from each other, and a plurality of battery cells (6) mounted in said metal profile (2) in thermal contact with the thermal transfer fins (3) is disclosed. The battery module is characterized in that the thermal transfer fins (3) are configured to exert pressure on the battery cells (6), and in that the thermal contact between the thermal transfer fins (3) and the battery cells (6) is at least partly mediated by heat-conducting filler material (7) and electrically insulating material (8) positioned between the thermal transfer fins (3) and the battery cells (6) for improving thermal transfer between the battery cells (6) and the thermal transfer fins (3). Also a battery cell (6), a metal profile (2), and a method for assembling a battery module are disclosed.