Battery System Assembly Press for Thermal Contact and Modular Replacement
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Solution Overview
Problem
The manufacturing of electric vehicle battery systems faces challenges in ensuring reliable electrical connections, efficient cooling, and cost-effective assembly of thousands of individual battery cells into modular systems that can be easily installed and replaced.
Innovation Solution
A method and apparatus involving a battery system assembly press with slides and rails to press battery cells against a cooling duct for effective thermal contact, and the use of trays with indentations to support and electrically connect the cells, allowing for efficient assembly and replacement of battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery cells are assembled into modular systems with thousands of individual cells, then the battery system can be installed and replaced when necessary, but the manufacturing complexity and assembly time increase significantly
Solution Approach 1:
The battery system is divided into modular battery packs, each containing organized groups of battery cells. This segmentation allows individual packs to be manufactured separately and replaced as complete units, simplifying the overall system assembly while maintaining replaceability.
Solution Approach 2:
Battery cells are pre-assembled into organized groups within trays before final pack assembly. This preliminary organization reduces on-site assembly complexity and enables standardized replacement procedures.
2Temperature
If cooling ducts are placed between battery cell groups, then thermal management efficiency improves, but the manufacturing precision requirements increase
Solution Approach 1:
Cooling ducts are strategically positioned in specific locations between battery cell groups where thermal management is most critical. This localized approach optimizes cooling efficiency while reducing the overall precision requirements compared to uniform cooling across all cells.
Solution Approach 2:
Trays serve as intermediary structures that hold battery cells in organized groups and provide reference surfaces for cooling duct placement. This intermediary framework simplifies the positioning process and reduces manufacturing precision requirements.
3Temperature
If battery cells are pressed against cooling ducts with high force, then thermal contact improves, but the risk of cell deformation or damage increases
Solution Approach 1:
The cooling ducts are designed with flexible or deformable characteristics that allow them to conform to the battery cell surfaces under pressing force. This flexibility enables good thermal contact while distributing the mechanical stress to prevent cell damage.
Solution Approach 2:
The pressing mechanism is designed to apply force gradually and uniformly, with built-in compliance elements that cushion the impact and prevent sudden excessive forces that could damage battery cells while still achieving adequate thermal contact.
4Reliability
If trays with indentations are used to hold battery cells, then electrical connections and cell support improve, but the manufacturing cost increases
Solution Approach 1:
The trays are designed to perform multiple functions simultaneously: providing mechanical support for battery cells, establishing electrical connections through integrated contacts, and organizing cells into groups for efficient cooling. This multi-functionality reduces the need for separate components, lowering overall manufacturing costs.
Solution Approach 2:
The tray structure merges the support function and electrical connection function into a single component. The indentations provide mechanical support while integrated conductive elements establish electrical connections, eliminating the need for separate support structures and connection components.
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 approach enhances thermal management, ensures reliable electrical connections, and simplifies the manufacturing process, reducing costs and improving the service life of battery systems while enabling efficient use of space in electric vehicles.
Implementation Method 1
applying a first force to the first plurality of battery cells and a second force to the second plurality of batteries, where the first and second forces cause the first and second pluralities of battery cells to press against the cooling duct
Data Source
AI summary
A method of manufacturing a battery pack is disclosed. The method includes placing first and second sets of battery cells in first and second battery cell holders of a battery system assembly press, placing a cooling duct in a gap between the first and second sets of battery cells, and applying a first and second forces to the first and second sets of battery cells to cause the first and second sets of battery cells to respectively press against first and second sides of the cooling duct. The method also includes, while applying the first and second forces, placing the first and second plurality of battery cells in a first tray configured to hold the first and second plurality of battery cells.