Battery Cell Strip Array for Uniform Thermal Management
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Solution Overview
Problem
Existing battery assemblies for electrified vehicles face challenges in manufacturing efficiency and thermal management due to complex cell stacking and cooling requirements, which affect the ease of assembly and uniform cooling of battery cells.
Innovation Solution
A battery assembly design featuring a single continuous layer of electrolyte with electrodes arranged on either side, supported by carrier strips, allowing for easy alignment and rolling around a spool, along with a thermal exchange plate for efficient cooling, facilitating easier manufacturing and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cell stacking methods are used, then battery cells can be assembled, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The battery pack is divided into multiple cell strips, each comprising a sequence of battery cells arranged in series. Each cell strip is further segmented into groups of cells connected in parallel. This segmentation allows for modular assembly where cell strips can be manufactured and assembled independently, reducing overall manufacturing complexity and improving ease of assembly.
Solution Approach 2:
The patent transitions from traditional three-dimensional stacking arrangements to a planar, two-dimensional arrangement where battery cells are organized in rows and columns within cell strips. This dimensional change simplifies the assembly process by enabling flat-layer construction that is easier to manufacture and assemble, while still achieving the desired electrical configuration through strategic parallel and series connections within the planar structure.
2Temperature
If traditional cooling arrangements are used, then battery cells can be cooled, but thermal management uniformity decreases
Solution Approach 1:
The cooling system is merged with the cell strip structure itself, where cooling channels are integrated directly into the cell strip assembly. This integration ensures that all battery cells within a cell strip are cooled uniformly by the same cooling fluid flow path, eliminating thermal management hot spots and improving overall temperature uniformity across the battery pack.
Solution Approach 2:
The cell strip structure serves multiple functions: it provides mechanical support for the battery cells, establishes electrical connections through parallel and series configurations, and simultaneously acts as the cooling structure with integrated channels. This multi-functionality reduces the need for separate cooling components, simplifying the overall cooling system while improving thermal management uniformity.
3Quantity of substance
If complex cell arrangements are used, then battery capacity can be increased, but packaging efficiency decreases
Solution Approach 1:
The patent employs a planar arrangement of battery cells in rows and columns within cell strips, transitioning from complex three-dimensional stacking to a flattened, two-dimensional configuration. This dimensional change improves packaging efficiency by reducing the vertical space required while maintaining or increasing battery capacity through optimized parallel and series connections within the planar cell strip structure.
Solution Approach 2:
The battery pack is segmented into multiple cell strips that can be efficiently packaged in layers. Each cell strip contains a specific number of cells arranged in a compact linear sequence, allowing for optimized space utilization. The segmentation enables flexible arrangement of cell strips to maximize packaging efficiency while achieving the desired total battery capacity through the combination of multiple cell strips in parallel and series configurations.
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 simplifies the manufacturing process, enhances packaging efficiency, and provides uniform thermal management, improving the performance and reliability of battery assemblies for electrified vehicles.
Implementation Method 1
the layer of electrolyte is provided by a layer of electrically insulative and ionically conductive material
Implementation Method 2
a thermal exchange plate adjacent the spool, the thermal exchange plate coupled to the metal foil layer
Data Source
AI summary
This disclosure relates to a battery assembly, such as a battery assembly for an electrified vehicle, and a corresponding method. An example battery assembly includes a layer of electrolyte, a plurality of first electrodes arranged on a first side of the layer of electrolyte, a plurality of second electrodes arranged on a second side of the layer of electrolyte, and a plurality of battery cells. Further, each of the battery cells includes a portion of the layer of electrolyte, one of the first electrodes, and one of the second electrodes.