Battery Module Intermediate Walls Composite Copper Aluminum
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Solution Overview
Problem
Existing battery modules face challenges in efficiently connecting multiple electrode assemblies in series while maintaining a compact, lightweight, and cost-effective design, and in preventing electrolyte leakage and thermal management.
Innovation Solution
A battery module with a housing containing compartments separated by intermediate walls made of copper and aluminum, which are electrically connected to the electrodes and embedded within an insulating polymer material, allowing for series connection and thermal conductivity, and featuring a structured surface to prevent electrolyte leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intermediate walls are made of electrically conducting material for series connection, then electrical connection efficiency is improved, but thermal management capability deteriorates
Solution Approach 1:
The intermediate walls are constructed as composite structures with an electrically conducting layer (copper or aluminum) for series connection and a thermally conducting layer (such as graphite or heat-conductive polymer) for thermal management. This composite design allows simultaneous achievement of electrical connectivity and thermal dissipation functions within the same component.
Solution Approach 2:
The intermediate walls serve multiple functions simultaneously: they provide electrical connection between adjacent electrode assemblies for series configuration, act as structural separators between compartments, and function as heat dissipation pathways through their thermally conducting properties. This multi-functionality resolves the contradiction by integrating both electrical and thermal management capabilities into a single component.
2Reliability
If housing material is electrically insulating for safety, then electrical safety is improved, but thermal conductivity deteriorates
Solution Approach 1:
The housing is constructed as a composite structure with an electrically insulating base material (such as polyphenylene sulfide or polyamide) for electrical safety and thermal stability, combined with thermally conductive fillers or layers (such as aluminum oxide, boron nitride, or heat-conductive polymers) to enhance heat dissipation. This composite design maintains electrical insulation while improving thermal conductivity.
Solution Approach 2:
The housing exhibits non-uniform thermal properties with enhanced thermal conductivity in specific regions where heat dissipation is most needed, such as areas adjacent to electrode assemblies or integrated cooling channels, while maintaining electrical insulation throughout. This localized enhancement resolves the contradiction by providing thermal management where required without compromising overall electrical safety.
3Stability of the object's composition
If intermediate walls are embedded in housing material, then structural stability is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The intermediate walls are pre-formed with embedding features or mounting structures before being integrated into the housing. This preliminary preparation allows for simplified assembly where the intermediate walls can be directly inserted or attached to pre-prepared receptacles in the housing, reducing manufacturing complexity while maintaining structural stability.
Solution Approach 2:
The manufacturing processes for the housing and intermediate walls are combined or integrated, such as co-molding techniques where intermediate walls are embedded during the housing molding process itself, or using the same material system for both components. This merging of processes reduces the number of separate manufacturing steps and lowers overall complexity while ensuring structural integration.
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 enables a compact, lightweight, and cost-effective battery module with efficient electrical connection and thermal management, preventing electrolyte leakage and allowing for flexible accommodation of various electrode assembly types.
Implementation Method 1
The intermediate walls are made of at least one electrically conducting material, in particular metal... the intermediate walls comprise a first layer made of copper and a second layer made of aluminium
Implementation Method 2
edges of the first layer comprise a structured surface... An adhesive layer is situated between the first component and the second component for integral connection
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention refers to a battery module (2), comprising a housing (20) with several compartments (45), intermediate walls (30) separating adjacent compartments (45) and electrode assemblies (10) arranged in the compartments (45). The intermediate walls (30) comprise at least a first layer (31) made of copper and a second layer (32) made of aluminium, the intermediate walls (30) are inserted into the material of the housing (20), such that edges of the intermediate walls (30) are surrounded by the material of the housing (20), and edges (81) of the first layer (31) comprise a structured surface.