Battery Pack Cell Holder Alignment and Thermal Sealing
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Solution Overview
Problem
Existing battery pack assemblies face challenges in efficiently managing and sealing multiple battery cells, leading to potential misalignment, overheating, and inadequate heat dissipation, which can result in reduced performance and safety concerns.
Innovation Solution
A battery pack assembly comprising a plurality of cell holders with a frame chassis and side walls to maintain alignment, a metallic battery cage for enclosure, a battery management circuit board for monitoring, and a heat sink with a heat exchange plate for efficient heat dissipation, along with a sealing ring for hermetic sealing and pressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple battery cells are assembled in a compact arrangement, then space utilization is improved, but alignment precision deteriorates leading to misalignment
Solution Approach 1:
The battery pack is segmented into multiple modular cell holders, each designed to accommodate specific battery cells. This segmentation allows for standardized alignment features in each module while maintaining compact overall arrangement, resolving the conflict between space utilization and alignment precision.
Solution Approach 2:
Alignment pins and guide structures act as intermediary elements between cell holders and battery cells. These intermediaries ensure precise positioning and alignment during assembly, preventing misalignment even in compact multi-cell configurations.
2Object-affected harmful factors
If battery cells are enclosed in a sealed structure, then protection against water and dust is improved, but heat dissipation deteriorates
Solution Approach 1:
The sealing structure uses gaskets and flexible sealing rings that can be integrated with thermal management pathways. These flexible sealing elements allow for thermal expansion while maintaining seal integrity, and can be designed with thermal conductivity properties to facilitate heat dissipation through the sealed structure.
Solution Approach 2:
The thermal management system is nested within the sealed enclosure structure. Heat sinks and thermal conduction pathways are integrated inside the sealed battery pack, allowing heat to be dissipated through thermally conductive sealed walls while maintaining protection against water and dust.
3Reliability
If a comprehensive sealing system is implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The gasket and sealing ring structures serve multiple functions simultaneously: providing water and dust sealing, accommodating thermal expansion, facilitating thermal conduction, and enabling pressure equalization. This multi-functionality reduces the need for separate components, maintaining reliability while reducing overall system complexity.
Solution Approach 2:
The sealing system is merged with the structural framework of the battery pack. Sealing rings are integrated into the cell holder assemblies and enclosure structures, combining mechanical support and sealing functions into unified components, thereby reducing complexity while maintaining reliable sealing.
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
The solution ensures proper alignment and connection of battery cells, effective heat management, and enhanced sealing, thereby improving the performance, safety, and reliability of the battery pack by maintaining cell alignment, managing heat efficiently, and preventing water and dust ingress.
Implementation Method 1
heat sink with a heat exchange plate for efficient heat dissipation
Implementation Method 2
heat sink with a heat exchange plate for efficient heat dissipation
Implementation Method 3
sealing ring for hermetic sealing and pressure relief
Data Source
AI summary
A battery with a plurality of battery cells disposed on a plurality of cell holders. Each battery cell holder holds two battery cells. The plurality of cell holders with the battery cells are enclosed in a battery case and placed inside an external case with a top cover.