Battery Pack Insulation Layer for Direct Cooling Without Module Frames
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Solution Overview
Problem
Conventional battery modules face insulation issues due to the lack of insulation performance in heat conductive resin layers, which can lead to damage when in direct contact with battery cells, and they also have suboptimal cooling efficiency.
Innovation Solution
A battery pack design featuring an adhesive layer with insulation properties applied to the lower surface of each battery cell stack, a heat conductive resin layer between the adhesive layer and the pack housing, and partitioned module regions within the pack housing to enhance insulation and cooling efficiency, while eliminating the need for a module frame to reduce weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat conductive resin layer is used between the battery cell stack and pack housing, then cooling efficiency is improved, but insulation performance deteriorates leading to damage risk
Solution Approach 1:
The thermal management system is segmented into multiple functional layers: a heat conductive resin layer for thermal dissipation and an insulating cover layer for electrical insulation. This segmentation allows each layer to perform its specific function optimally without compromising the other, resolving the contradiction between cooling efficiency and insulation performance.
Solution Approach 2:
The patent employs composite material structure by combining heat conductive resin with an insulating cover made of insulating material. This composite approach enables simultaneous achievement of thermal conduction (through the resin) and electrical insulation (through the cover), eliminating the trade-off between cooling efficiency and insulation performance.
2Stability of the object's composition
If a module frame is used to protect battery cells, then structural stability is improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the protective function with the thermal management function by integrating the insulating cover into the heat dissipation structure. The insulating cover serves dual purposes: providing electrical insulation and facilitating heat conduction to the pack housing, thereby eliminating the need for a separate module frame and reducing overall structural complexity.
Solution Approach 2:
The insulating cover is designed as a multi-functional component that simultaneously provides electrical insulation, structural protection, and thermal management. This universal component replaces multiple separate components (protective frame and thermal management layer), reducing device complexity while maintaining structural stability.
3Temperature
If heat conductive resin layer is applied directly to battery cell surface, then cooling efficiency is improved, but risk of cell damage increases due to lack of insulation
Solution Approach 1:
The insulating cover acts as an intermediary layer between the battery cell and the heat conductive resin. This intermediary provides electrical insulation to prevent short circuits while allowing thermal energy to pass through to the resin layer, thus enabling heat dissipation without compromising cell safety.
Solution Approach 2:
The insulating cover is applied beforehand as a protective barrier on the battery cell surface before the heat conductive resin is applied. This prior cushioning prevents direct contact between the resin and cell, eliminating the risk of electrical damage while maintaining the intended thermal management function.
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 maintains insulation performance while improving cooling efficiency by using an insulating adhesive layer and heat conductive resin layers, reducing the risk of damage and enhancing structural stability, and allowing for direct heat transfer from battery cells to the pack frame, thus preventing overheating.
Implementation Method 1
the adhesive layer has an insulation property
Implementation Method 2
a heat conductive resin layer located between the adhesive layer and the lower pack housing
Data Source
AI summary
A battery pack includes a battery cell stack that is formed by stacking a plurality of battery cells, an adhesive layer that is applied to the lower surface of the battery cell stack, a lower pack housing that has a plurality of module regions and on which the battery cell stack is mounted, and a heat conductive resin layer that is located between the adhesive layer and the lower pack housing, wherein the adhesive layer has an insulation property.