Battery Module Insulation Structure for Cell Stack Isolation
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Solution Overview
Problem
Conventional battery modules lack adequate insulation between the battery cell stack and the module frame, which can lead to reduced insulation performance and potential electrical issues.
Innovation Solution
A battery module design that includes an insulating member formed to wrap the upper surface and both side surfaces of the battery cell stack, coupled with a fixing member that secures the insulating member to the busbar frame, ensuring comprehensive insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating film is arranged only on the upper surface part of the battery cell stack, then the structure is simple, but insulation is not ensured between the battery cell stack and the module frame
Solution Approach 1:
The insulating member is divided into multiple functional parts: an upper surface part that contacts the battery cell stack and side surface parts that extend downward along the module frame. This segmentation allows the insulating member to provide comprehensive insulation coverage while maintaining structural clarity and ease of assembly.
Solution Approach 2:
The insulating member extends from a two-dimensional film configuration into a three-dimensional structure by forming side surface parts that wrap around the battery cell stack. This dimensional transformation enables the insulating member to cover both upper and side surfaces, ensuring complete insulation between the battery cell stack and module frame.
2Reliability
If the insulating member is not fixed to the busbar frame, then the structure is simpler, but the fixing force and stability are insufficient
Solution Approach 1:
The fixing member integrates multiple functions into a single component: it connects the insulating member to the busbar frame while also providing structural support and positioning. This merging of functions reduces the overall number of separate parts while ensuring secure fixation of the insulating member.
Solution Approach 2:
The fixing member acts as an intermediary element between the insulating member and the busbar frame, creating a reliable mechanical connection. This intermediary component ensures that the insulating member is securely positioned without requiring direct integration between the insulating member and frame structures.
Data Source
AI summary
A battery module including a battery cell stack in which a plurality of battery cells are stacked; a module frame that houses the battery cell stack; a busbar frame that covers front and rear surfaces of the battery cell stack; an insulating member that includes an upper surface part and both side surface parts, and is formed so as to wrap the upper surface and both side surfaces of the battery cell stack between the battery cell stack and the module frame; and a fixing member that couples the upper surface part of the insulating member and both side upper end parts of the busbar frame.