Insulated End Plate Structure for Compact Battery Modules
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Solution Overview
Problem
Existing battery modules face challenges in reducing size while maintaining high energy density and ensuring sufficient insulation and stiffness, often requiring additional insulating components that increase module size and complexity.
Innovation Solution
A battery module design featuring a metal end plate with an insulating coating on its entire surface except for the welding portion, which reduces the need for additional insulating components and enhances insulation and stiffness without increasing module size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic insulating plate is added to secure insulation performance, then insulation performance is improved, but the size of the battery module increases and stiffness is reduced
Solution Approach 1:
The patent combines the insulating plate and end plate into a single integrated component. The end plate includes an insulating plate portion and a metal plate portion that are structurally merged, eliminating the need for separate insulating components while maintaining insulation performance between the battery cell assembly and end plate
Solution Approach 2:
The end plate is constructed as a composite structure combining insulating material (for the insulating plate portion) and metal material (for the metal plate portion). This composite design provides both insulation functionality and structural stiffness without requiring additional separate components
2Reliability
If a plastic insulating plate is added to secure insulation performance, then insulation performance is improved, but the number of parts and assembly complexity increases
Solution Approach 1:
The patent merges multiple functions into a single end plate component. The end plate simultaneously provides structural support, insulation, and electrical isolation, thereby reducing the total number of parts and simplifying the assembly process
3Reliability
If a plastic insulating plate is added to secure insulation performance, then insulation performance is improved, but the stiffness of the battery module is reduced
Solution Approach 1:
The end plate uses a composite structure where the metal plate portion provides high stiffness and structural strength, while the insulating plate portion provides insulation. The metal material compensates for the lower stiffness of plastic materials while maintaining insulation performance through the composite design
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 increases energy density by reducing module size, secures sufficient insulation performance, and improves the stiffness of the battery module, addressing the limitations of conventional designs.
Implementation Method 1
an insulating coating portion coating an entire surface of the main body portion except for the welding portion
Implementation Method 2
a welding portion welding-coupled with the module frame
Data Source
AI summary
A battery module includes a battery cell assembly in which a plurality of battery cells are stacked adjacent to each other side by side; a module frame receiving the battery cell assembly; and an end plate disposed at one end of the battery cell assembly in a length direction, wherein the end plate includes a main body portion including a welding portion welding-coupled with the module frame and an insulating coating portion coating an entire surface of the main body portion except for the welding portion.