Battery Module Spacer and Insulation Sheet Design
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Solution Overview
Problem
Existing battery modules lack sufficient stiffness to absorb internal or external pressures and have inadequate anti-penetration characteristics, which can lead to safety issues such as swelling and potential explosions due to external conductor penetration.
Innovation Solution
A battery module design featuring spacers between adjacent cells for elastic deformation and multi-layer insulation sheets with a net-like cross-section to absorb compressive forces and prevent conductor penetration, utilizing different materials for spacers and insulation sheets to enhance mechanical stability and anti-penetration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-material insulation structures are used, then manufacturing is simple, but stiffness and anti-penetration characteristics are insufficient
Solution Approach 1:
The patent applies composite materials by combining a foam spacer layer with a heat-shrinkable tube layer to create a multi-functional insulation structure. The foam spacer provides mechanical support and stiffness, while the heat-shrinkable tube provides anti-penetration characteristics and electrical insulation. This composite structure resolves the contradiction by achieving enhanced strength properties without requiring complex multi-component assembly.
Solution Approach 2:
The foam spacer is designed to serve multiple functions simultaneously: it provides mechanical stiffness to maintain structural integrity, acts as an electrical insulator, and functions as a buffer to absorb swelling pressures between battery cells. This multi-functionality approach resolves the contradiction by reducing the need for separate components while achieving the required performance levels.
2Strength
If rigid structures are used to resist pressure, then stiffness is improved, but ability to absorb swelling pressure is reduced
Solution Approach 1:
The patent utilizes the elastic properties of the foam spacer material, which can change its density and compressibility parameters in response to applied pressure. The foam structure allows controlled compression under swelling pressure while maintaining structural integrity, resolving the contradiction between stiffness and pressure absorption capability through material parameter optimization.
Solution Approach 2:
The heat-shrinkable tube layer acts as a flexible protective shell that can deform elastically under pressure while maintaining its insulating function. This flexible layer works in conjunction with the foam spacer to provide both pressure resistance and swelling absorption, resolving the contradiction between rigid stiffness and flexible pressure accommodation.
3Reliability
If insulation sheets are placed in opening of spacer, then anti-penetration characteristics are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent merges the insulation sheet placement with the spacer structure by integrating the heat-shrinkable tube directly onto the foam spacer. This combination ensures that the insulation layer is automatically positioned correctly during assembly, eliminating the need for separate positioning steps and reducing manufacturing precision requirements while maintaining anti-penetration characteristics.
Solution Approach 2:
The heat-shrinkable tube is pre-formed and attached to the foam spacer before final assembly into the battery module. This preliminary preparation ensures correct positioning and orientation, reducing the precision requirements during the main assembly process while guaranteeing the insulation layer will be properly positioned to provide anti-penetration protection.
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 effectively absorbs compressive forces and swelling pressures, maintaining constant pressure between cells and preventing conductor penetration, thereby enhancing safety and stability of the battery module.
Implementation Method 1
The spacer may undergo an elastic deformation while tending to spread in a left, right, upward, or downward direction in response to a compressive force applied thereto in the forward or backward direction so as to absorb the compressive force applied in the forward or backward direction
Implementation Method 2
The multi-layer insulation sheet may be formed of an insulating, elastic material
Implementation Method 3
The multi-layer insulation sheet may be formed of an insulating, elastic material
Data Source
AI summary
A battery module includes battery cells arranged adjacent to each other along a first direction, a spacer between neighboring battery cells, and a multi-layer insulation sheet between the neighboring battery cells together with the spacer, the multi-layer insulation sheet including a plurality of insulation layers extending in parallel with surfaces of the battery cells.