Battery Cell Assembly with Tab-Slot Coupling and Cooling Apertures
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Solution Overview
Problem
Existing battery cell assemblies face challenges in securely holding battery cells and efficiently managing heat dissipation, particularly in compact configurations where space and cooling efficiency are critical.
Innovation Solution
The use of frame members with extending tabs and slots for secure coupling, combined with a cooling manifold or fin that allows fluid flow through apertures, enables effective holding and cooling of battery cells, utilizing rectangular ring-shaped portions with specific tab and cross-member designs to facilitate airflow and coolant passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If frame members with tabs and slots are used to securely hold battery cells, then mechanical stability and cell retention are improved, but device complexity increases due to additional coupling features
Solution Approach 1:
The frame members are segmented into modular components with standardized tabs and slots that can be independently manufactured and assembled. This segmentation allows for easier manufacturing while achieving secure mechanical retention of battery cells through the distributed tab-slot coupling system.
Solution Approach 2:
The tabs and slots are designed as universal coupling features that serve multiple functions: mechanical retention of battery cells, structural alignment of frame members, and integration points for cooling manifolds. This multi-functionality reduces the need for separate components, thereby managing complexity.
2Temperature
If cooling manifolds with apertures are integrated into frame members, then heat dissipation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling manifold is merged with the frame member structure, integrating thermal management functionality into the existing mechanical framework. This combination eliminates the need for separate cooling component installation and reduces overall manufacturing steps while maintaining effective heat dissipation through the aperture network.
Solution Approach 2:
The frame member incorporates a porous-like structure with multiple apertures distributed throughout the cooling manifold regions. This aperture configuration enables efficient coolant flow and heat dissipation while the apertures can be formed through standard manufacturing processes such as injection molding or drilling, managing manufacturing complexity.
3Reliability
If multiple coupling features are added to frame members, then reliability of cell retention is improved, but ease of assembly deteriorates
Solution Approach 1:
The tabs and slots are pre-configured in specific patterns and orientations during frame member manufacturing. This preliminary arrangement of coupling features ensures proper alignment and simplifies the assembly process, as components naturally guide themselves into correct positions without requiring complex alignment procedures during assembly.
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 configuration securely holds battery cells and enhances cooling efficiency by allowing airflow and coolant circulation, improving thermal management and overall performance in battery cell assemblies.
Implementation Method 1
a cooling manifold or fin disposed between the battery cells, wherein each of the first frame member and the second frame member includes a rectangular ring-shaped portion having apertures extending through the rectangular ring-shaped portion, and wherein the cooling manifold or fin is fluidly coupled to an inlet fluid conduit and an outlet fluid conduit through the apertures
Implementation Method 2
The rectangular ring-shaped portion further includes a spacer portion extending away from a rear surface of the rectangular ring-shaped portion, the spacer portion defining a plurality of holes for allowing air flow therethrough into an open region defined by the rectangular ring-shaped portion
Implementation Method 3
the spacer portion defining a plurality of holes for allowing air flow therethrough into an open region defined by the rectangular ring-shaped portion
Data Source
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AI summary
A battery cell assembly in accordance with an exemplary embodiment is provided. The assembly includes a first frame member having a first plurality of tabs extending away from a first peripheral edge of the first frame member. Each tab of the first plurality of tabs has a first coupling feature at a distal end of the respective tab. The assembly further includes a second frame member having a plurality of slots extending into a second peripheral edge of the second frame member. The assembly further includes a battery cell disposed between the first and second frame members, and each first coupling feature of each tab of the first plurality of tabs is configured to engage a respective slot of the plurality of slots of the second frame member to fixedly hold the first and second frame members together.