Integrated Battery Dividing Wall With Conductor Rail Housing

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Solution Overview

Problem

The production costs and cycle times for manufacturing batteries are high due to the complex assembly of dividing walls and conductor rail housings, which allows flames and gases to spread between cell modules, increasing the risk of thermal runaway and fire.

Innovation Solution

A dividing wall assembly where the conductor rail housing and dividing wall are formed as one part, using a mineral material with a sandwich structure to reduce the number of components and prevent gas and flame transfer, and incorporating a protection cap arrangement and tolerance compensation mat for enhanced safety and assembly efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If separate dividing wall and conductor rail housing components are used, then assembly flexibility is improved, but production costs and cycle times increase

Engineering Contradiction:

Improveassembly flexibilityVSAvoidproduction cycle time

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent combines the dividing wall and conductor rail housing into a single integrated component. The conductor rail housing is formed as one part with the dividing wall, eliminating the need for separate assembly steps and reducing production cycle time while maintaining assembly flexibility through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated dividing wall assembly serves multiple functions simultaneously: it provides thermal and electrical isolation between cell modules (dividing wall function) while also housing and protecting the conductor rail (conductor rail housing function). This multi-functionality reduces the total number of components and assembly steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If separate dividing wall and conductor rail housing components are used, then manufacturing flexibility is improved, but production costs increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent merges the dividing wall and conductor rail housing into a single integrated component, reducing the total number of parts from two separate components to one. This integration maintains manufacturing flexibility through modular design while eliminating the need for additional fasteners, seals, and assembly hardware that would be required for separate components.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If openings are provided in dividing walls for conductor rails, then electrical connection is enabled, but flame and gas spread between cell modules is facilitated

Engineering Contradiction:

Improveelectrical connectionVSAvoidflame and gas spread

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a conductor rail housing as an intermediary structure that houses the conductor rail and provides thermal and gas barrier protection. The housing acts as a mediator that enables electrical connection while preventing direct exposure of the opening to flames and hot gases, thus blocking the spread pathway.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The conductor rail housing serves as a protective shell that encloses the conductor rail and seals the opening in the dividing wall. This shell structure prevents flame and gas penetration while allowing the conductor rail to pass through, maintaining electrical connectivity without compromising thermal and gas barrier integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

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 reduces production costs and cycle times, enhances fire protection by minimizing gaps for gas and flame transfer, and increases the safety of batteries by preventing thermal runaway and electrical shorts.

Implementation Method 1

a dividing wall having a sandwich structure in an orthogonal direction to the wall plane, wherein a sandwich core comprises a mineral material or consists entirely thereof

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The conductor rail housing is formed as one part with the dividing wall... enhances fire protection by minimizing gaps for gas and flame transfer

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20240291094A1Dividing Wall Assembly for a Battery Housing, Battery and Vehicle

Publication Date: 2024.08.29 SYNGENTA CROP PROTECITON AG

AI summary

Please substitute the new Abstract submitted herewith for the original Abstract:A dividing wall assembly for a battery housing. The dividing wall assembly has a dividing wall that lies in a wall plane spanned by a longitudinal direction and a vertical direction orthogonal to the longitudinal direction, at least one conductor rail housing, and at least one conductor rail received in the conductor rail housing. The conductor rail housing is formed as one part with the dividing wall.