Battery Module Mounting Insulation for Heat and Swelling Control
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Solution Overview
Problem
Battery cells in vehicle propulsion systems are temperature-sensitive, prone to mechanical stress, and face issues with swelling, which can lead to reduced operational range, energy efficiency, and lifespan, as well as increased risk of damage from vibration and impact.
Innovation Solution
A battery module with a thermal insulation unit positioned between the casing and mounting section to reduce heat transfer, allowing for more efficient temperature regulation, accommodating swelling, and providing mechanical protection, while being cost-efficient to manufacture and assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery cells are mounted in a confined space to protect them from mechanical damage, then mechanical protection is improved, but heat dissipation deteriorates and internal pressure increases due to swelling
Solution Approach 1:
The patent employs a flexible mounting section with absorptive elements that can deform and expand to accommodate battery cell swelling while maintaining mechanical protection. This flexible structure prevents rigid constraints that would trap heat, allowing thermal management while providing protective enclosure.
Solution Approach 2:
The mounting structure is segmented into multiple independent mounting sections, each capable of accommodating individual battery cell expansion. This segmentation allows localized adjustment for swelling cells while maintaining overall structural integrity and heat dissipation pathways through the modular design.
2Quantity of substance
If battery cells are tightly mounted to maximize space utilization, then energy density is improved, but temperature uniformity deteriorates and mechanical stress increases
Solution Approach 1:
The flexible mounting section with absorptive elements provides a compliant interface that maintains intimate thermal contact between battery cells and the mounting structure, ensuring uniform heat distribution while accommodating volume changes that would otherwise create thermal gaps in tightly packed configurations.
Solution Approach 2:
The absorptive elements are pre-positioned in the mounting sections to provide cushioning and accommodation for expected battery cell swelling during operation. This beforehand preparation ensures that temperature uniformity is maintained throughout the battery pack's lifecycle despite cell expansion and contraction cycles.
3Strength
If rigid mounting structures are used to protect battery cells from vibration and impact, then mechanical strength is improved, but adaptability to cell swelling deteriorates
Solution Approach 1:
The mounting structure incorporates flexible elements and absorptive materials that can deform under vibration and impact loads while maintaining protective function. This flexibility allows the structure to adapt to battery cell swelling without compromising the mechanical strength needed to protect against external forces.
Solution Approach 2:
The mounting structure transitions from a static rigid design to a dynamic system where absorptive elements can change their mechanical properties in response to external forces. During vibration or impact, these elements provide damping and compliance, while during normal operation they maintain secure mounting while accommodating swelling.
4Temperature
If thermal management system operates continuously to maintain optimal battery temperature, then temperature control is improved, but energy consumption increases
Solution Approach 1:
The flexible mounting structure with absorptive elements passively contributes to thermal management by providing thermal contact and heat distribution throughout the battery pack. This self-service function reduces the burden on active thermal management systems, allowing them to operate less intensively and consume less energy while maintaining temperature control.
Solution Approach 2:
The mounting structure creates thermal equipotential conditions throughout the battery pack by ensuring uniform thermal contact between all battery cells and the mounting structure. This reduces temperature gradients and hot spots, allowing the thermal management system to operate more efficiently with lower energy consumption to maintain uniform temperature.
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 temperature uniformity and lifespan of battery cells, improves mechanical protection, and maintains energy efficiency, thereby extending the operational range and durability of the vehicle's battery system.
Implementation Method 1
a thermal insulation unit (9) positioned between the casing (3) and the mounting section (7)
Data Source
AI summary
A battery module for a vehicle is disclosed. The battery module comprises a casing configured to accommodate a number of battery cells and a mounting section configured to receive a fastening element for mounting the battery module to a further component of the vehicle. The battery module comprises a thermal insulation unit positioned between the casing and the mounting section. The present disclosure further relates to a battery pack for a vehicle and a vehicle comprising a battery pack.