Battery Module Frame With Integrated Insulation for Higher Energy Density
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Solution Overview
Problem
Conventional battery modules face challenges in securing insulation performance without additional components, leading to decreased energy density and complex assembly processes.
Innovation Solution
A battery module design featuring an insulation coating layer integrated within the frame, combined with a thermally conductive resin layer, which secures insulation without separate components, enhancing energy density and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member is added as a separate component between the battery cell stack and the frame, then insulation performance is improved, but energy density decreases and assembly complexity increases
Solution Approach 1:
The patent merges the insulating member with the frame by forming the insulating member as an integrated part of the frame structure. The insulating member is formed to have a shape that fits within the frame, with insulating layers on internal surfaces and a bottom surface, creating a unified component that provides both structural support and electrical insulation without requiring separate assembly steps.
Solution Approach 2:
The frame is designed to serve multiple functions simultaneously: it provides mechanical support for the battery cell stack, acts as a structural housing, and incorporates the insulating member as an integral part to provide electrical insulation. This multi-functional design eliminates the need for separate insulating components while maintaining all necessary functions.
2Reliability
If an insulating member is added as a separate component between the battery cell stack and the frame, then insulation performance is improved, but assembly difficulty increases
Solution Approach 1:
The insulating member is merged with the frame as an integrated component, eliminating the need for separate assembly steps. The insulating member is formed with a specific shape that includes insulating layers on the internal surfaces and bottom surface of the frame, creating a unified structure that reduces assembly complexity.
Solution Approach 2:
The insulating member is pre-formed as an integral part of the frame structure during frame manufacturing, rather than being added as a separate component during assembly. This preliminary integration of the insulating function into the frame manufacturing process simplifies the overall assembly process.
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 integrated insulation coating layer improves insulation performance, increases energy density, reduces manufacturing costs, and simplifies assembly by eliminating the need for additional insulating components.
Implementation Method 1
an insulation coating layer having an upper surface, a lower surface, a left surface and a right surface respectively formed on the upper surface, the lower surface, the left surface and the right surface
Implementation Method 2
a thermally conductive resin layer between the lower portion of the battery cell stack, and the frame and the insulation coating layer
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked; a frame formed on upper, lower, left and right surfaces to house the battery cell stack; and an insulation coating layer formed on the upper, lower, left and right surfaces inside the frame, wherein a plurality of grooves corresponding to a bottom shape of the battery cell stack are formed on a lower surface inside the frame, and wherein a lower surface of the insulation coating layer is formed to be coated on the upper surface of the plurality of grooves.