Battery Module Vent Hole Insulation for Short-Circuit Prevention
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Solution Overview
Problem
Existing battery modules face a high risk of short circuits due to insufficient insulation distance between the housing's exhaust holes and the battery cell, particularly when the inner circumferential surface of these holes is exposed, which can lead to accidents.
Innovation Solution
A battery module structure featuring a hole insulator that covers the inner circumferential surface of the exhaust hole, increasing the insulation distance by extending from the insulation sheet or using a hole insulation member to cover the entire inner surface, thereby preventing short circuits while allowing gas discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If an exhaust hole is provided in the cover for discharging gas, then gas discharge function is improved, but insulation distance between the battery cell and the cover becomes very short increasing short circuit risk
Solution Approach 1:
An insulating member is introduced as an intermediary component between the battery cell and the exhaust hole in the cover. This insulating member extends into the exhaust hole to increase the insulation distance, while the cover still maintains its gas discharge function through the exhaust hole. The insulating member acts as a mediator that resolves the conflict between gas discharge capability and insulation safety.
Solution Approach 2:
The insulating member is specifically positioned at the critical location where the exhaust hole passes through the cover, providing localized insulation enhancement only where needed. This allows the cover to maintain its overall gas discharge function while creating a localized insulated pathway that prevents short circuits between the battery cell and the conductive cover.
2Strength
If the cover is made of conductive metal material, then structural strength is improved, but short circuit risk increases due to electrical conductivity
Solution Approach 1:
The battery module employs a composite structure combining conductive metal cover material with insulating materials. The cover itself remains conductive metal for structural strength, while the insulating member (made of insulating material) is integrated within the cover structure to provide electrical insulation. This composite approach allows both structural strength and electrical insulation requirements to be satisfied simultaneously.
Solution Approach 2:
The insulating member serves as an intermediary between the conductive cover and the battery cell, allowing the cover to maintain its conductive metal properties for structural strength while the insulating member prevents direct electrical contact with the battery cell, thus eliminating the short circuit risk associated with conductive covers.
3Reliability
If insulation sheet is attached to the inner surface of the cover, then insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The insulating member is integrated with the cover structure, forming a unified component rather than a separate attachment. The insulating member and cover are designed as a combined structure where the insulating member is positioned within the cover's thickness, eliminating the need for separate attachment steps and reducing manufacturing complexity while maintaining insulation performance.
Solution Approach 2:
The cover structure is designed as a composite component incorporating both the conductive metal cover material and the insulating member in a single integrated structure. This composite design allows the insulation function to be built-in during cover manufacturing, avoiding additional attachment steps and simplifying the overall manufacturing process.
Data Source
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AI summary
The present invention provides a structure of a battery module comprising: a battery cell; a housing accommodating the battery cell; a cover constituting one side of the housing and provided with a first hole connecting inside and outside of the housing; an insulation sheet provided between the battery cell and the cover and having a second hole disposed at a position corresponding to the first hole; and a hole insulator covering at least a portion of an inner circumferential surface of the first hole.