Modular Battery Pack Insulation Cover for Safer Service Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery pack designs lack adequate insulation protection between conductive components and the container, posing safety risks during assembly and use, and hinder maintenance and repair of individual battery modules due to the absence of a high-voltage protection unit and independent module containers.
Innovation Solution
A battery pack design featuring multiple modules with a flexible printed circuit board and conductive connecting plates, each equipped with an insulation cover that fixes onto a battens, providing insulation between conductive components and the container, and allowing for independent module protection and repair, while also enhancing assembly efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an integral plastic sheet is used to cover the top of the large battery module, then insulation protection is provided, but maintenance and protection of individual modules becomes difficult and insulation between adjacent modules is compromised
Solution Approach 1:
The patent divides the battery pack into independent modular units, each with its own insulation cover. This segmentation allows individual modules to be maintained or replaced without affecting other modules, while still providing comprehensive insulation protection for each unit.
Solution Approach 2:
Each battery module is equipped with its own dedicated insulation cover rather than a single integral cover for the entire battery pack. This local quality approach ensures that insulation protection is tailored to each module's specific needs and allows independent access to individual modules for maintenance.
2Quantity of substance
If the separator and module container are cancelled to achieve high energy density, then energy density improves, but safety and insulation protection are reduced
Solution Approach 1:
The patent uses flexible printed circuit boards as insulation barriers between conductive components and the battery pack container. These thin film structures provide effective insulation protection without occupying significant space, thus maintaining high energy density while ensuring safety.
Solution Approach 2:
The insulation cover acts as an intermediary element between conductive components and the battery pack container, providing necessary electrical insulation and safety protection without requiring traditional bulky separators or module containers.
3Device complexity
If no independent module container is used, then assembly complexity is reduced and energy density increases, but insulation protection between adjacent modules is compromised
Solution Approach 1:
The patent combines the insulation cover with the module structure itself, integrating insulation functionality directly into each module rather than relying on separate container structures. This merging approach provides adequate insulation protection while maintaining simple assembly and high energy density.
Data Source
AI summary
The present disclosure discloses a battery pack, including a plurality of battery modules. Each battery module includes: a battery row including a plurality of battery cells, each battery cell includes two electrodes and electrodes of all battery cells form two electrode rows arranging in the longitudinal direction; a flexible printed circuit board located between the two electrode rows; and two conductive connecting plate rows located on two sides of the flexible printed circuit board in the transverse direction respectively, each conductive connecting plate row includes a plurality of conductive connecting plates arranged in the longitudinal direction and spaced apart from each other, and each conductive connecting plate is electrically connected to the flexible printed circuit board and a corresponding electrode of a corresponding electrode row. Each battery module further includes an insulation cover covering and fixed to a top of the battery row to insulate each battery module from outside.