Modular Battery Compression Bladder for High Voltage Safety
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Solution Overview
Problem
Modular batteries used in hybrid electric vehicles and plug-in hybrid electric vehicles require high power delivery and safety features, particularly to ensure reliable electrical contact and manage pressure within the battery stack to prevent electrical arcing and shock hazards at high voltages.
Innovation Solution
A modular battery design incorporating a pressurizable bladder to force battery cells against each other, maintaining electrical contact and monitoring pressure to ensure safety, using a housing with interconnectors and a pressure sensor system to manage and log pressure data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are connected in series to deliver high power, then power delivery capability is improved, but the risk of electrical arcing and shock hazards increases
Solution Approach 1:
A compressible interconnector is introduced as an intermediary element between battery cells connected in series. This interconnector maintains electrical continuity while providing mechanical compression that secures cell connections and reduces arcing hazards through consistent pressure contact.
Solution Approach 2:
A bladder is filled with inert gas (such as nitrogen) and pressurized to apply compression force on the battery cells and interconnectors. This pneumatic system maintains consistent pressure to ensure reliable electrical contact and reduce arcing risks without requiring complex mechanical fastening systems.
2Reliability
If a compressible interconnector is used to maintain electrical contact between cells, then electrical contact reliability is improved, but the complexity of the battery assembly increases
Solution Approach 1:
The electrical connector and mechanical compression functions are merged into a single compressible interconnector component. This integrated design simplifies assembly by eliminating separate fastening mechanisms while maintaining both electrical continuity and mechanical stability.
Solution Approach 2:
The compressible interconnector serves multiple functions simultaneously: it provides electrical connection between cells, maintains mechanical compression for contact reliability, and acts as a structural element within the battery assembly. This multi-functionality reduces the number of separate components needed.
3Stress or pressure
If a bladder is pressurized to maintain compression on battery cells, then contact pressure consistency is improved, but the device complexity and safety monitoring requirements increase
Solution Approach 1:
A pressure sensor is integrated into the bladder system to provide feedback on the internal pressure. This feedback mechanism allows monitoring of compression force applied to battery cells, enabling detection of pressure changes that may indicate cell expansion or system faults.
Solution Approach 2:
The bladder system is designed to automatically maintain compression pressure through the inert gas fill, reducing the need for active mechanical adjustment mechanisms. The system self-regulates to maintain contact pressure through the pressurized gas acting on the flexible bladder.
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 enables reliable high-voltage electrical power delivery with reduced risk of electrical arcing and shock hazards, ensuring efficient and safe operation of modular batteries in high-power applications by maintaining consistent pressure and monitoring for potential failures.
Implementation Method 1
a pressurizable bladder forcing the first battery cell against the second battery cell
Data Source
AI summary
A modular battery includes a housing, a first battery cell having a first electrode surface, a second battery cell having a second electrode surface, and a pressurizable bladder forcing the first battery cell against the second battery cell.