Cylindrical Battery Cell Sizing for Dense Pack Layouts
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Solution Overview
Problem
The low space utilization rate in battery designs limits the energy density of batteries, as the circular cross-section of cylindrical battery cells leads to wasted space and reduced capacity when packed within a box body, increasing manufacturing costs and complexity.
Innovation Solution
The battery design optimizes space utilization by controlling the diameter of cylindrical battery cells and the thickness of thermal management members, ensuring the ratio of diameter to accommodation cavity area is ≤25×10−6, and strategically placing thermal management and insulation members to enhance thermal management while minimizing space occupancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the diameter of cylindrical battery cells is increased, then the manufacturing cost and complexity are reduced, but the space utilization rate in the box body decreases due to wasted corner regions
Solution Approach 1:
The patent applies asymmetry by using cylindrical battery cells with non-uniform diameter distribution within the box body. Specifically, battery cells with different diameters are arranged in different regions - larger diameter cells in certain areas and smaller diameter cells in others - to better fill the rectangular space and reduce wasted corner regions, thereby improving space utilization while maintaining manufacturing feasibility
Solution Approach 2:
The patent implements local quality by varying the diameter of battery cells according to their specific positions within the box body. Different regions of the box body are filled with battery cells of appropriately sized diameters to optimize space utilization in each local area, rather than using uniform diameter cells throughout
2Area of stationary object
If the diameter of cylindrical battery cells is decreased, then the space utilization rate in the box body is improved, but the manufacturing difficulty and cost increase
Solution Approach 1:
The patent applies segmentation by dividing the battery pack into multiple modules, each containing battery cells of specific diameter ranges. This segmentation allows the system to achieve high space utilization through optimized arrangement while maintaining manufacturing feasibility by producing cells in standardized diameter groups rather than requiring a continuous range of small-diameter cells
Solution Approach 2:
The patent implements parameter changes by optimizing the diameter parameter of battery cells to specific ranges (e.g., 15-20mm, 20-25mm, etc.) based on position within the box body. This parameter optimization achieves high space utilization while avoiding the manufacturing difficulties associated with excessively small diameters
3Temperature
If thermal management members are added between battery cells, then thermal management effectiveness is improved, but the space utilization rate decreases due to additional space occupancy
Solution Approach 1:
The patent applies merging by integrating thermal management members with the structural components of the battery pack. The thermal management members are combined with support structures, spacing elements, or structural members, allowing them to perform thermal management functions without occupying additional space beyond what is already required for structural support and cell spacing
Data Source
AI summary
A battery and an electric device are provided. The battery includes: a plurality of battery cells, and each battery cell being cylindrical; and a box body, provided with an accommodation cavity configured for accommodating the plurality of battery cells. The area of the accommodation cavity on a plane perpendicular to the central axis of the battery cell is S, the diameter of a single battery cell is A, satisfying A/S≤25×10−6.