Heat-Shrink Film Battery Module for Integrated Cell Stack Insulation
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Solution Overview
Problem
Existing battery modules for vehicles require multiple insulation components, increasing manufacturing costs and complexity, and often fail to achieve complete insulation due to gaps at component boundaries.
Innovation Solution
A battery module structure using a thermal shrink film to cover the cell stack assembly, integrating insulation functions while reducing the number of components, and incorporating a thermal conductive unit for heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating components are individually applied to every part where insulation is required, then insulation effectiveness is improved, but the number of components increases, manufacturing cost increases, and manufacturing process complexity increases
Solution Approach 1:
The patent merges multiple separate insulating components into a single integrated insulating structure that covers the entire cell stack assembly. Instead of applying individual insulating components to different parts (between cells, between bus bar frames and cells, between end plates and cells), the invention uses one continuous insulating layer that performs all insulation functions simultaneously, thereby reducing component count while maintaining insulation effectiveness
Solution Approach 2:
The single insulating structure serves multiple insulation functions at once: it insulates between battery cells, between bus bar frames and cells, between end plates and cells, and provides overall structural coverage. This multi-functional design eliminates the need for specialized insulating components for each interface, simplifying the assembly while ensuring comprehensive insulation
2Reliability
If insulating components are individually applied to every part where insulation is required, then insulation effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
By combining multiple insulating components into a single integrated structure, the patent reduces the total number of parts that need to be manufactured, stored, and assembled. This consolidation lowers material costs, reduces manufacturing complexity, and decreases assembly time, thereby reducing overall manufacturing cost while maintaining comprehensive insulation coverage
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
Secures effective insulation and heat dissipation without additional components, improving manufacturing efficiency and reducing costs while maintaining high energy density.
Implementation Method 1
a thermal shrink film configured to cover the cell stack assembly
Data Source
AI summary
A battery module includes a cell stack assembly. The cell stack assembly includes a cell stack having a plurality of battery cells and a buss bar frame assembly covering a first side of the cell stack an da second side of the cell stack. The battery module further includes a thermal shrink film covering the cell stack assembly. The battery module further includes a module housing accommodating the cell stack assembly covered by the thermal shrink film. The battery module further includes an end plate covering an opening at a first side of the module housing or a second side of the module housing.