One-piece Battery Housing with Compression Plugs
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Solution Overview
Problem
Prismatic battery cells in electric vehicles experience swelling due to pressure buildup, leading to shifting internal components and degradation of chemical properties, which reduces efficiency and product life, necessitating effective compression to maintain chemical integrity.
Innovation Solution
A housing system with a one-piece casing and adjustable plug mechanism that applies compressive force to prismatic cells, using detention mechanisms to securely couple the plug to the casing, allowing for adjustable compression to accommodate cell variances and providing structural rigidity to prevent swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If prismatic battery cells are used in electric vehicles, then energy storage capacity is improved, but structural stability deteriorates due to swelling from pressure buildup
Solution Approach 1:
The patent employs a flexible membrane or film structure within the housing that can accommodate the swelling of prismatic battery cells while maintaining containment. This flexible barrier allows the cell to expand during charging cycles without rigidly constraining it, thereby preventing structural damage while maintaining the benefits of using high-capacity prismatic cells.
2Stability of the object's composition
If compression is applied to prismatic cells to prevent swelling, then structural stability is improved, but device complexity increases due to additional compression mechanisms
Solution Approach 1:
The patent integrates the compression function directly into the housing structure itself, merging the support and compression roles with the containment function. The housing is designed with built-in flexible diaphragms or spring-loaded walls that provide continuous gentle compression to counteract swelling, eliminating the need for separate, complex compression mechanisms while maintaining structural stability.
3Adaptability or versatility
If multiple separate components are used in the housing system, then adaptability to cell variances is improved, but manufacturing complexity increases
Solution Approach 1:
The patent designs a universal housing structure with standardized features that can accommodate variations in battery cell dimensions and specifications. The housing includes adjustable mounting points, flexible sealing mechanisms, and modular internal components that can be configured for different cell types, allowing a single design to serve multiple cell variants without requiring custom manufacturing for each specification.
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 extends the life and efficiency of prismatic cells by limiting swelling, reducing manufacturing complexity and costs through a simplified design with a single-piece casing and adjustable compression, ensuring robustness across varying cell dimensions and tolerances.
Implementation Method 1
it would be desirable to provide compression to the prismatic cells to protect their chemical integrity
Implementation Method 2
A battery module housing system may include a one-piece casing and a plug coupled to the casing
Data Source
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AI summary
Systems are disclosed for battery modules with housing systems. In accordance with disclosed embodiments, the housing system may include a four-walled casing (e.g., no top/bottom) with at least one hole and plug that couples with the hole in the casing using a detention mechanism. The casing may house multiple prismatic cells in a face-to-face arrangement. The plug may extend through the hole in the casing to contact and apply a compressive force to the cells within the casing. Further, the casing may have the hole and plug assembly on parallel sides, enabling the compressive force to be applied to the cells from both directions. The compressive force may retain the cells in the casing and limit the swelling of the cells to maintain their product life. The housing system may also include a cooling system in contact with the bottom of the cells and/or compression plates to distribute the compressive force evenly on the prismatic cells.