Battery Module with Insulating Separating Body for Thermal Isolation
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Solution Overview
Problem
Lithium-ion battery modules face safety concerns due to the low energy density of steel-shell cylindrical batteries and the high cost and safety risks associated with large-capacity rectangular batteries, which are difficult to assemble safely and efficiently.
Innovation Solution
A battery module design featuring mono-batteries arranged with adjacent side surfaces, enclosed in an insulative casing with a supporting frame and a separating body injected through potting holes to isolate and insulate each battery, improving safety and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel-shell cylindrical lithium-ion batteries are used, then technology maturity is improved, but energy density deteriorates
Solution Approach 1:
The battery module uses multiple small-capacity cylindrical batteries (e.g., 2Ah each) instead of a single large-capacity battery. By segmenting the total capacity into multiple units (e.g., 100Ah total capacity formed by 50 batteries), the design achieves high energy density while maintaining the technological maturity and safety of cylindrical battery form factors.
2Quantity of substance
If large-capacity rectangular batteries are used, then energy density is improved, but safety performance deteriorates
Solution Approach 1:
The module divides the battery system into multiple independent small-capacity cylindrical cells, each with its own safety characteristics. This segmentation prevents a single point of failure from compromising the entire system, as each cell is electrically and physically isolated by insulating structures.
Solution Approach 2:
Insulating structures (insulating columns and insulating coatings) are introduced as intermediary elements between adjacent batteries. These intermediaries provide electrical isolation and physical buffering, preventing direct contact between cells and reducing the propagation of thermal or electrical failures across the module.
3Use of energy by moving object
If multiple mono-batteries are connected in series, then sustainability is improved, but safety risk deteriorates
Solution Approach 1:
Insulating structures are positioned between series-connected batteries to provide electrical isolation. This intermediary protection ensures that if one battery fails or experiences a short circuit, the failure cannot directly propagate to adjacent batteries in the series string, thereby maintaining system sustainability while reducing safety risks.
Solution Approach 2:
The insulating structures serve as pre-established protective barriers that cushion against potential failure propagation. By having these isolation structures in place before any failure occurs, the system is pre-prepared to contain failures locally, preventing cascading effects across the entire series-connected module.
4Reliability
If insulating structures are added between batteries, then safety is improved, but device complexity deteriorates
Solution Approach 1:
The insulating functions are merged into integrated structural elements. Insulating columns serve both as mechanical support structures and as electrical isolation barriers, while insulating coatings on battery surfaces provide both protection and isolation. This merging reduces the number of separate components needed while maintaining safety functions.
Solution Approach 2:
The insulating structures are designed to perform multiple functions simultaneously: electrical isolation, mechanical support, thermal management assistance, and physical protection. This multi-functionality reduces overall system complexity by eliminating the need for separate components for each function.
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 design enhances safety by isolating failing batteries, simplifies structure, reduces size and cost, and improves energy density, while maintaining effective heat dissipation and shock absorption.
Implementation Method 1
a separating body which is formed by injecting via the potting holes and curing and is potted among the adjacent mono-batteries, so as to allow the plurality of mono-batteries to be insulated and isolated from each other
Implementation Method 2
a separating body which is formed by injecting via the potting holes and curing and is potted among the adjacent mono-batteries, so as to allow the plurality of mono-batteries to be insulated and isolated from each other
Implementation Method 3
a supporting frame fixed in the insulative casing, provided with a potting hole, and holding the plurality of mono-batteries therein
Data Source
AI summary
The present disclosure provides a battery module, which comprises: a plurality of mono-batteries arranged in a manner that side surfaces are adjacent to each other; an insulative casing receiving the plurality of mono-batteries; a supporting frame fixed in the insulative casing, provided with a potting hole, and holding the plurality of mono-batteries therein; and a separating body which is formed by injecting via the potting holes and curing and is potted among the adjacent mono-batteries, so as to allow the plurality of mono-batteries to be insulated and isolated from each other. When one mono-battery is involved in a safety problem and leaks, other mono-batteries are not affected due to the isolation of the separating body potted among the adjacent mono-batteries, so as to improve the safety performance of the battery module. In addition, the battery module has the advantages of simple structure, small size, and low cost.