Cut-Line Insulating Sheet for Battery Module Thermal Isolation
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Solution Overview
Problem
In densely packed battery modules, abnormal phenomena such as high temperature, gas generation, and sparking can rapidly spread between battery cells, leading to severe fire accidents due to the lack of effective insulation.
Innovation Solution
A battery module design featuring an insulating sheet with cut lines and through-holes covering the battery cells, along with sidewalls and a holder to prevent the spread of heat and flames, allowing for localized separation of affected areas and maintaining insulation over unaffected cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are densely packed to enhance output and capacity, then productivity and energy density improve, but the spread of abnormal phenomena (heat, gas, sparks) between cells increases
Solution Approach 1:
The insulating sheet is divided into multiple independent insulating pieces separated by cut lines. Each insulating piece covers individual battery cells or groups of cells, creating segmented isolation zones. This segmentation allows the abnormal phenomena to be contained within specific cell groups while preventing spread to other groups, thus maintaining high cell density while reducing hazard propagation.
Solution Approach 2:
The insulating sheet provides localized insulation properties at critical interfaces between battery cells. By positioning insulating pieces at specific locations where heat and spark propagation risks are highest, the design achieves effective isolation without requiring complete coverage of all cell surfaces, thereby maintaining productivity while enhancing safety.
2Reliability
If insulating material is placed between battery cells to prevent spread of abnormal phenomena, then safety improves, but device complexity and space requirements increase
Solution Approach 1:
The insulating sheet serves multiple functions simultaneously: it provides thermal insulation, electrical insulation, mechanical support, and structural organization. By integrating these multiple functions into a single component, the design achieves enhanced safety without proportionally increasing device complexity. The insulating sheet also facilitates cell arrangement and provides a mounting structure for other components.
Solution Approach 2:
The insulating sheet is designed as a thin, flexible structure that can conform to the battery cell arrangement. This thin-film approach provides effective insulation without adding significant volume or structural complexity. The flexibility allows the insulating sheet to adapt to different battery configurations and densities.
3Reliability
If insulating sheet is made continuous to maximize insulation effect, then fire spread prevention improves, but adaptability to cell boundaries and ventilation requirements deteriorate
Solution Approach 1:
The insulating sheet is segmented into multiple independent pieces separated by cut lines that align with battery cell boundaries. This segmentation allows each insulating piece to precisely fit and adapt to specific cell groups while maintaining effective insulation within those groups. The cut lines also create natural ventilation channels and allow for thermal expansion without compromising the overall insulation effectiveness.
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 suppresses the propagation of abnormal phenomena, delaying fire and explosion spread, thereby reducing damage to life and property by isolating affected cells and maintaining insulation across the module.
Implementation Method 1
an insulating sheet formed of an insulating material and including a middle portion covering a first surface of the multiple battery cells
Implementation Method 2
Each of the battery cells may be formed on the first surface thereof with a vent, through which a gas generated inside the battery cell is released, and a vent hole may be formed through the middle portion in a thickness direction thereof to expose the vent through the middle portion
Data Source
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AI summary
Disclosed in an example embodiment is a battery module includes: multiple battery cells arranged in a first direction; and an insulating sheet formed of an insulating material and including a middle portion covering a first surface of the multiple battery cells, the middle portion being formed with at least one cut line extending in a second direction.