Battery Module Separator Structure for Heat Isolation and Cell Positioning

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Solution Overview

Problem

Conventional battery modules experience degradation due to excessive temperature increase and thermal conduction between adjacent batteries, leading to performance issues and difficulty in maintaining electrical connections.

Innovation Solution

Incorporation of a thermal conduction suppressor with lower thermal conductivity and a position regulator with higher rigidity, positioned to insulate and stabilize the battery stack, preventing overheating and maintaining electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If batteries are stacked closely together to increase power density, then productivity and power output are improved, but thermal conduction between adjacent batteries increases causing overheating and performance degradation

Engineering Contradiction:

Improvepower densityVSAvoidbattery temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

A separator is introduced as an intermediary component between adjacent batteries. The separator includes a thermal conduction suppressor portion with low thermal conductivity to block heat transfer, and a position regulator portion with high rigidity to maintain battery positioning and electrical connections. This mediator structure prevents direct thermal contact while maintaining structural integrity and electrical connectivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If a separator is introduced to insulate between batteries, then thermal conduction is suppressed, but device complexity increases due to additional components

Engineering Contradiction:

Improvethermal insulationVSAvoidseparator structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The separator is segmented into two distinct functional portions: a thermal conduction suppressor portion made of heat-resistant low-thermal-conductivity material, and a position regulator portion made of high-rigidity material. This segmentation allows each portion to optimize its specific function while together forming a complete separator solution that addresses both thermal insulation and structural requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator utilizes composite material construction by combining materials with different thermal and mechanical properties. The thermal conduction suppressor portion uses heat-resistant material with low thermal conductivity, while the position regulator portion uses material with high rigidity. This composite approach enables the separator to simultaneously achieve thermal insulation and structural support functions.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If batteries are not sufficiently fixed in the battery module, then ease of manufacture is improved, but reliability decreases due to difficulty in maintaining electrical connections

Engineering Contradiction:

Improveassembly easeVSAvoidelectrical connection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The position regulator portion of the separator serves multiple functions simultaneously: it maintains the positional relationship between adjacent batteries, prevents battery displacement during operation, and ensures stable electrical connections between batteries. This multi-functional design achieves reliable battery fixation without complicating the manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively suppresses thermal conduction and maintains battery position, thereby preventing overheating and enhancing the performance and stability of the battery module.

Implementation Method 1

The thermal conduction suppressor has lower thermal conductivity than the position regulator and suppresses thermal conduction between the adjoining two of the batteries

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The position regulator has greater rigidity than the thermal conduction suppressor, has a dimension in a stacked direction of the batteries equal to or greater than a dimension of the thermal conduction suppressor in the stacked direction, and abuts the adjoining two of the batteries to regulate a position of each of the adjoining two of the batteries in the stacked direction

Methodology Applied

Scientific EffectRigidity:

Data Source

PatentUS12355046B2Battery module

Publication Date: 2025.07.08 SANYO ELECTRIC CO LTD

AI summary

The battery module includes a plurality of batteries stacked together, and separator disposed between an adjoining two of the plurality of batteries and configured to insulate between the adjoining two of batteries. Separator includes thermal conduction suppressor and position regulator. Thermal conduction suppressor has lower thermal conductivity than position regulator and suppresses thermal conduction between the adjoining two of batteries. Position regulator has higher rigidity than thermal conduction suppressor, has dimension in stacked direction of batteries equal to or greater than dimension of thermal conduction suppressor in stacked direction, and abuts the adjoining two of batteries to regulate a position of each of the adjoining two of batteries in stacked direction.