Battery Pack Heat Sink Insulation for High-Voltage Module Safety
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Solution Overview
Problem
There is a need for a battery pack with improved insulation performance and safety, particularly for high-voltage modules used in vehicles, where sufficient insulation distances between battery modules and the pack frame are crucial to prevent electrical hazards.
Innovation Solution
The battery pack design includes a pack frame with heat sinks and heat transfer members, where insulating members are attached to the heat sinks and positioned between the heat transfer members and the battery modules, enhancing insulation performance and safety by securing adequate creepage distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery modules are mounted in a pack frame with sufficient insulation distances, then insulation performance and safety are improved, but device complexity and space requirements increase
Solution Approach 1:
The patent introduces insulating members as intermediary components positioned between the battery modules and the pack frame. These insulating members act as mediators that provide the necessary insulation distance and electrical isolation without requiring complex structural modifications to the pack frame itself, thereby improving insulation performance while maintaining relatively simple device structure
Solution Approach 2:
The insulation function is segmented into separate insulating members that can be independently positioned and attached to the pack frame. This segmentation allows the insulation requirement to be fulfilled through discrete components rather than requiring the entire pack structure to be redesigned with increased complexity
2Reliability
If insulation distances between battery modules and pack frame are increased, then safety is improved, but available space for battery modules decreases
Solution Approach 1:
By introducing thin insulating members as intermediary components, the patent achieves the required insulation distance with minimal space consumption. These insulating members provide adequate electrical isolation and safety clearance without significantly reducing the volume available for battery module placement
Solution Approach 2:
The patent optimizes the thickness and material properties of the insulating members to achieve the minimum required insulation distance while minimizing the space occupied. By carefully selecting insulation parameters, the design fulfills safety requirements without unnecessarily reducing battery module space
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
This design effectively improves insulation performance and safety by ensuring sufficient insulation distances and efficient heat transfer, addressing the challenges of high-voltage applications.
Implementation Method 1
a heat transfer member positioned between the heat sink and the lower surfaces of the plurality of battery modules
Implementation Method 2
an insulating member may be attached to at least one end portion of the heat sink. At least a portion of the insulating member may be positioned between the heat transfer member and the heat sink
Data Source
AI summary
An exemplary embodiment provides a battery pack including: a pack frame configured to accommodate a plurality of battery modules; a heat sink positioned on lower surfaces of the battery modules; and a heat transfer member positioned between the heat sink and the lower surfaces of the battery modules. An insulating member is attached to at least one end portion of the heat sink.