Battery Module Insulation via Dedicated Members

Solution Overview

Problem

Existing battery modules require additional anodizing or painting processes for insulation, which can be damaged easily and are difficult to apply on complex shapes, posing risks of short-circuits and electric shocks.

Innovation Solution

A battery module design incorporating a battery cell assembly with first and second insulating members, a cooling plate, and an insulation hook to provide effective insulation without the need for additional anodizing or painting, using polycarbonate materials for the second insulating member to ensure module insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If anodizing or painting process is performed on metal members for insulation, then insulating property is improved, but manufacturing complexity and susceptibility to damage increase

Engineering Contradiction:

Improveinsulating propertyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the insulation function from the metal members themselves and transfers it to separate insulating members. Instead of treating metal members with insulating coatings, the design uses dedicated insulating components (such as insulating plates or sleeves) that are assembled with the metal members during module assembly. This eliminates the need for anodizing or painting processes while maintaining insulation reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces insulating members as intermediary components between metal members (cooling fins, end plates) and battery cells. These insulating members act as mediators that prevent direct electrical contact between conductive parts, thereby ensuring insulation without requiring surface treatment of the metal members themselves.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If anodizing or painting process is performed on metal members for insulation, then insulating property is improved, but ease of manufacture deteriorates due to difficulty in applying complex shapes

Engineering Contradiction:

Improveinsulating propertyVSAvoidease of applying insulation process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the insulation function from the metal members themselves and transfers it to separate insulating members. Instead of treating metal members with insulating coatings, the design uses dedicated insulating components (such as insulating plates or sleeves) that are assembled with the metal members during module assembly. This eliminates the need for anodizing or painting processes while maintaining insulation reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the material parameter of certain components from conductive metal to insulating materials. By selecting insulating members made from materials with appropriate electrical resistance properties, the design ensures insulation functionality without requiring surface treatment processes, thereby simplifying manufacturing for complex-shaped components.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If additional anodizing or painting process is performed for insulation, then insulating property is improved, but productivity decreases due to additional processing steps

Engineering Contradiction:

Improveinsulating propertyVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the insulation function with the assembly process itself. Insulating members are integrated into the module assembly structure, and their installation is combined with the assembly of other components like cooling fins and end plates. This eliminates the need for separate anodizing or painting process steps, thereby improving manufacturing productivity while maintaining insulation reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the insulation function from the metal members themselves and transfers it to separate insulating members. Instead of treating metal members with insulating coatings, the design uses dedicated insulating components (such as insulating plates or sleeves) that are assembled with the metal members during module assembly. This eliminates the need for anodizing or painting processes while maintaining insulation reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10811738B2Battery module, battery pack comprising battery module, and vehicle comprising battery pack

Publication Date: 2020.10.20 LG ENERGY SOLUTION LTD

AI summary

A battery modules includes a battery cell assembly including at least one battery cell, and at least one cooling fin configured to contact the at least one battery cell and to be exposed on opposite side parts of the battery cell assembly and a side part perpendicular to the opposite side parts, a first end plate including at least one first insulating member mounted contacting the at least one cooling fin exposed on the opposite side parts of the battery cell assembly, and configured to support the opposite side parts of the battery cell assembly, a second end plate coupled to the first end plate, and configured to support the side part of the battery cell assembly, a cooling plate between the second end plate and the battery cell assembly, and at least one second insulating member arranged between the cooling plate and the at least one cooling fin.