Battery Module Insulating Member for Deformation Control

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Solution Overview

Problem

Conventional battery modules face issues with deformation and positional instability of battery cell stacks during assembly, leading to inconsistent electrode lead positioning and compromised insulation properties.

Innovation Solution

Incorporation of an insulating member that continuously covers the lower and side surfaces of the battery cell stack, minimizing pressure-induced deformation and maintaining electrode lead position, while enhancing insulation and assembly stability through a thermal conductive resin layer and extension parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery cell stack is pressed with a pressure jig to weld electrode leads, then the electrode leads are welded to form a cell assembly, but the battery cell and battery cell stack deform and the electrode lead position becomes unstable

Engineering Contradiction:

Improveelectrode lead positioning stabilityVSAvoidbattery cell stack deformation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

An insulating member is introduced as an intermediary component between the pressure jig and the battery cell stack during welding operations. This insulating member distributes the pressing force uniformly across the battery cell stack, preventing localized deformation while maintaining stable electrode lead positioning during the welding process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating member is pre-installed on the battery cell stack before the welding operation begins. This preliminary action ensures that the battery cell stack is already protected and properly positioned before the pressure jig applies force, preventing deformation and position instability during the welding process

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the battery cell stack is pressed during assembly, then the cell assembly is formed, but the position of the electrode lead part changes and becomes unfixed

Engineering Contradiction:

Improveassembly processVSAvoidelectrode lead part position

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The insulating member serves as a mediator that maintains the position of electrode leads during the assembly pressing operation. It allows the pressure jig to apply necessary force for assembly while preventing the electrode leads from shifting or becoming unfixed

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conventional assembly methods are used without additional insulation, then the assembly process is simpler, but the insulation property of the battery module is compromised

Engineering Contradiction:

Improveinsulation propertyVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating member performs multiple functions simultaneously: it provides electrical insulation between the battery cell stack and housing, maintains the position of electrode leads during assembly, and distributes pressing forces uniformly. This multi-functionality improves insulation properties without significantly increasing assembly complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 insulating member reduces deformation and improves assembly and insulation properties, ensuring stable electrode lead positioning and enhanced structural integrity within the battery module.

Implementation Method 1

a thermal conductive resin layer located at the bottom part of the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20220399622A1Battery module and method of manufacturing the same

Publication Date: 2022.12.15 LG ENERGY SOLUTION LTD

AI summary

A battery module including a stack of a plurality of battery cells; a housing for the battery cell stack; and an insulating member located between the battery cell stack and the housing. The insulating member is continuously formed on a lower surface and two side surfaces of the battery cell stack.