Battery Module Insulating Structure for Side-Surface Isolation
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Solution Overview
Problem
Conventional battery modules lack sufficient insulation between the battery cell stack and the module frame, particularly on the side surfaces, which compromises the overall insulation performance.
Innovation Solution
A battery module design that includes an insulating member covering the upper and side surfaces of the battery cell stack, coupled with a busbar frame via fixing members, ensuring comprehensive insulation and secure attachment.
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 insulating film can be easily manufactured and installed, but insulation is not ensured between the battery cell stack and the module frame on the side surfaces
Solution Approach 1:
The insulating member is divided into multiple segments: an upper surface insulating member covering the upper surface of the battery cell stack, and side surface insulating members covering the side surfaces. This segmentation allows each insulating component to be independently designed and positioned, ensuring comprehensive insulation coverage while maintaining manufacturing simplicity.
Solution Approach 2:
The insulating member extends from the upper surface dimension to the side surface dimension, creating a three-dimensional insulating structure. This dimensional extension ensures that insulation is provided not only on the upper surface but also on the side surfaces where the battery cell stack contacts the module frame.
2Reliability
If the insulating member is extended to cover both side surfaces and upper surface of the battery cell stack, then comprehensive insulation is achieved, but the structure becomes more complex and difficult to assemble
Solution Approach 1:
The insulating member is segmented into an upper surface insulating member and side surface insulating members that can be assembled separately. The side surface insulating members are positioned between the battery cell stack and the module frame, while the upper surface insulating member covers the top, allowing for simplified manufacturing and assembly processes.
Solution Approach 2:
The side surface insulating members act as intermediary components positioned between the battery cell stack and the module frame. This intermediary placement simplifies the overall structure by clearly defining the insulating function's location and making assembly more straightforward.
3Temperature
If only a thermally conductive resin layer is used at the bottom, then thermal management is achieved, but insulation between the battery cell stack and module frame on side surfaces is insufficient
Solution Approach 1:
Different regions of the battery module are assigned different functional qualities: the bottom surface uses a thermally conductive resin layer for heat dissipation, while the side surfaces use insulating members for electrical insulation. This local differentiation of material properties optimizes both thermal management and insulation performance simultaneously.
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes 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 the front and rear surfaces of the battery cell stack; an insulating member that is formed of 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.