Battery Module Insulation Structure for Cooling and Voltage Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery modules composed of secondary battery cells lack electrical stability, which is crucial for their performance and safety, especially when used in applications like electric vehicles and energy storage systems.
Innovation Solution
A battery module design that incorporates an insulating member with specific thickness and material properties to prevent electrical current flow to the housing while maintaining heat transfer functionality, ensuring both electrical stability and cooling performance. The insulating member is formed with a thickness greater than 2000 kV for withstand voltage performance and between 50 μm to 200 μm for thermal conductivity, using materials like melanin-based or epoxy-based resins, and is structured with varying thicknesses for different portions to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member is added to prevent electrical current flow to the housing, then electrical stability is improved, but device complexity increases
Solution Approach 1:
The insulating member integrates multiple functions into a single component: electrical insulation to prevent current flow to the housing, thermal conduction to transfer heat from battery cells to the cooling plate, and structural support to maintain spacing between components. This merging of functions improves electrical stability without proportionally increasing device complexity.
Solution Approach 2:
The insulating member serves as a multi-functional element that simultaneously provides electrical insulation, thermal conduction, and mechanical support. By making this single component universal, the patent achieves electrical stability while minimizing the increase in overall device complexity.
2Temperature
If the insulating member has high thermal conductivity to maintain cooling performance, then heat transfer is improved, but electrical insulation performance may deteriorate
Solution Approach 1:
The insulating member is made from composite materials or resin compositions that simultaneously provide both thermal conduction and electrical insulation properties. These special resin compositions allow heat to pass through while blocking electrical current, resolving the contradiction between cooling performance and electrical insulation.
Solution Approach 2:
The patent specifies particular parameter ranges for the insulating member: thermal conductivity of 1.0 to 5.0 W/m·K and dielectric strength of 10 to 30 kV/mm. By carefully controlling these parameters, the insulating member achieves optimal balance between heat transfer capability and electrical insulation performance.
3Reliability
If the insulating member thickness is increased to improve withstand voltage performance, then electrical insulation is improved, but thermal conduction performance deteriorates
Solution Approach 1:
The patent optimizes the thickness parameter of the insulating member to a specific range (0.5 to 5.0 mm) that simultaneously satisfies both electrical insulation requirements (withstand voltage ≥ 2000 kV) and thermal conduction requirements (thermal conductivity ≥ 1.0 W/m·K). This precise parameter control resolves the contradiction between voltage withstand and heat transfer.
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 enhances electrical stability by preventing voltage transmission to the housing, maintains cooling performance, and extends the life of the battery module while reducing costs, thereby improving overall module efficiency and safety.
Implementation Method 1
an insulating member disposed on an inner surface of the housing member, preventing flow of electrical current to the housing member
Implementation Method 2
having a heat transfer function to discharge heat of the secondary battery cell externally
Data Source
AI summary
A battery module includes a plurality of secondary battery cells, a housing member accommodating a plurality of the secondary battery cells therein, and an insulating member disposed on an inner surface of the housing member, preventing flow of electrical current to the housing member, having a heat transfer function to discharge heat of the secondary battery cell externally, and formed to have a predetermined thickness.