Battery Module Insulation Plate and Side Surface Plates
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Solution Overview
Problem
Existing battery modules are heavy and costly due to their complex structure, which compromises cooling performance by creating a complicated heat transfer path.
Innovation Solution
A battery module design that replaces the metal frame with an insulation plate and side surface plates, allowing direct contact between the battery cell stack and a thermally conductive layer, simplifying the cooling path and reducing weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal frame surrounds six surfaces of the battery cell stack and a thermally conductive resin layer is separately inserted, then the battery module structure is complete and protective, but the weight becomes relatively heavier
Solution Approach 1:
The patent combines the frame structure and thermally conductive resin layer into an integrated frame assembly. The frame is formed with recesses that directly receive and hold the thermally conductive resin layers, eliminating the need for separate insertion steps and reducing the number of discrete components while maintaining structural integrity and cooling functionality
Solution Approach 2:
The patent removes the end plates from the traditional six-surface enclosure, opening the front and rear surfaces of the battery cell stack. This extraction of unnecessary components reduces weight while the frame assembly with integrated thermal management continues to provide adequate structural support and cooling where required
2Stability of the object's composition
If the thermally conductive resin layer and frame are located between the heat sink and battery cell stack, then the structure is stable, but the cooling path becomes complicated and cooling performance decreases
Solution Approach 1:
The patent segments the frame into multiple frame assemblies, each with specific recesses positioned to receive thermally conductive resin layers at critical heat transfer locations. This segmentation allows the thermal management function to be distributed and optimized at different points along the battery cell stack, creating multiple direct thermal pathways to the heat sink rather than a single complicated path
Solution Approach 2:
The frame assemblies act as intermediaries that directly connect the battery cell stack to the heat sink through strategically positioned thermally conductive resin layers. The frame's recesses ensure optimal thermal contact between components, facilitating efficient heat transfer from the battery cells through the frame structure to the heat sink, thereby simplifying and optimizing the cooling path
3Reliability
If a metal frame and end plates are used to cover all surfaces of the battery cell stack, then the battery module is well-protected, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and removes the end plates from the traditional design, opening the front and rear surfaces of the battery module. The frame assemblies are reconfigured to provide necessary structural support and integration without requiring costly end plate components, thereby reducing material costs and simplifying the manufacturing process while maintaining adequate protection
Solution Approach 2:
The patent merges the structural support function and thermal management function into integrated frame assemblies. These frame assemblies perform multiple functions simultaneously - providing structural support, housing thermally conductive resin layers, and facilitating heat transfer - thereby eliminating the need for separate end plates and reducing the total component count and manufacturing complexity
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 simplified structure reduces the weight and manufacturing costs of the battery module while improving cooling performance by direct heat transfer from the battery cells to the thermally conductive layer and heat sink.
Implementation Method 1
a thermally conductive layer contacting the lower surface of the battery cell stack and a heat sink located on a lower side of the thermally conductive layer
Data Source
AI summary
A battery module includes: a battery cell stack in which a plurality of battery cells are stacked; an insulation plate covering a front surface or a rear surfaces of the battery cell stack; a busbar frame formed between the battery cell stack and the insulation plate; a sensing member connected to the busbar frame on an upper side of the battery cell stack; and side surface plates covering respective side surfaces of the battery cell stack, wherein each of the side surface plates includes a mounting part formed on an outer surface thereof, wherein a lower surface of the battery cell stack is opened, outermost battery cells of the plurality of battery cells and the side surface plates are coupled to each other, respectively, and the insulation plate is coupled with the busbar frame or at least one of the side surface plates to fix the plurality of battery cells.