Battery Module Insulation Foil for Thermal Contact Without Air Pockets
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Solution Overview
Problem
Cylindrical battery cells in traction batteries for electric vehicles face insulation resistance issues due to air bubbles in gap fillers, which can lead to safety-critical faults, and existing gap fillers are costly and limited in tolerance compensation.
Innovation Solution
A battery module design featuring electrically insulating foil on the temperature-control surfaces of battery cells, which provides electrical insulation between the cells and the temperature-control element, allowing for independent choice of thermally conductive elements and reducing the risk of air pockets, while also simplifying mounting and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gap filler is used to thermally link battery cells to temperature-control element, then thermal conductivity is improved, but air bubbles form causing insulation resistance issues
Solution Approach 1:
The solution divides the thermal linking function into two separate components: a thermally conductive element for heat transfer and an electrically insulating layer for electrical insulation. This segmentation allows each component to optimize its specific function without compromising the other, eliminating the insulation resistance issues caused by air bubbles in gap filler while maintaining effective thermal conductivity.
Solution Approach 2:
An electrically insulating layer is introduced as an intermediary between the battery cell and the temperature-control element. This intermediary layer provides electrical insulation while allowing the thermally conductive element to maintain thermal contact, thereby preventing insulation resistance failures while preserving thermal management effectiveness.
2Manufacturing precision
If gap filler is used to compensate geometrical tolerances, then tolerance compensation is improved, but air pockets form causing safety-critical faults
Solution Approach 1:
The solution separates the tolerance compensation function (performed by the thermally conductive element) from the electrical insulation function (performed by the insulating layer). This segmentation allows the thermally conductive element to effectively compensate for geometrical tolerances without the risk of air pockets compromising insulation resistance, as the insulating layer provides a reliable electrical barrier regardless of thermal contact quality.
Solution Approach 2:
The electrically insulating layer acts as a mediator that ensures reliable electrical insulation even when air pockets are present in the thermally conductive element. This intermediary layer prevents safety-critical insulation failures while allowing the thermally conductive element to perform its tolerance compensation function effectively.
3Loss of substance
If thermally conductive element thickness is reduced, then material costs are lowered, but thermal conductivity may be compromised
Solution Approach 1:
By segmenting the thermal management system into a thermally conductive element and an electrically insulating layer, the solution allows the thermally conductive element to be optimized for minimal thickness and material usage. The insulating layer compensates for any potential thermal conductivity loss by ensuring efficient thermal contact between the cell and temperature-control element, thereby reducing material costs while maintaining thermal performance.
Solution Approach 2:
The solution changes the parameters of the thermal management system by introducing a dedicated electrically insulating layer with optimized thickness and thermal properties. This parameter change allows the thermally conductive element to use minimal material while the insulating layer ensures sufficient thermal conductivity through proper contact pressure and material selection.
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 effectively reduces the risk of safety-critical insulation faults, lowers material and production costs, and enhances thermal conductivity by using a thinner thermally conductive element, while maintaining efficient electrical insulation and tolerance compensation.
Implementation Method 1
an insulation foil (7) arranged between the battery cells (5) and the temperature-control element (8)
Implementation Method 2
a thermally conductive element (6) which is arranged between the temperature-control surfaces (50) of the battery cells (5) and the temperature-control element (8)
Data Source
AI summary
The present invention relates to a battery module for the construction of a battery, preferably a traction battery for a vehicle, comprising at least two battery cells, preferably cylindrical battery cells, which are held in a cell holder and have temperature-control surfaces which are to be brought into thermally conductive contact with a temperature-control element of a battery housing, wherein an insulation foil arranged on the temperature-control surfaces of the battery cells is provided.