Vehicle Battery Housing Layout for Sealed Cells and Service Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lithium-ion energy stores for motor vehicles face high costs due to requirements for crash and bollard safety, humidity protection, thermal propagation control, and hazard resistance, with limited repairability and cooling efficiency.
Innovation Solution
A modular design with a hermetically sealed cell installation space and separate electronics compartment, featuring a burst-pressure resistant seal, plasto-elastic material for crash absorption, and a cooling system integrated between housing parts, allowing for self-extinguishing and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixed cell bonding to the housing is implemented to increase rigidity, then crash and bollard safety are improved, but the ability to repair the cell array in the event of a fault is lost
Solution Approach 1:
The housing is divided into a first housing part containing the cell array and a second housing part containing the electronics, connected by a housing middle part. This segmentation allows the cell array to be accessed and replaced independently while maintaining the structural integrity needed for crash and bollard safety.
Solution Approach 2:
The housing middle part is designed to be separable, transforming the fixed bonding into a dynamic, replaceable connection. This allows the cell array to be removed and replaced in the event of faults while maintaining rigid bonding during normal operation for safety.
2Reliability
If a hermetically sealed cell installation space is created, then protection against humidity and thermal propagation is improved, but the complexity of the housing structure increases
Solution Approach 1:
The housing is segmented into a first housing part for cells and a second housing part for electronics, with a housing middle part connecting them. This segmentation creates hermetic sealing around the cell array, protecting against humidity and thermal propagation while keeping the structure manageable.
Solution Approach 2:
The housing middle part acts as an intermediary element that provides hermetic sealing and structural connection between the cell housing and electronics housing, simplifying the overall design by consolidating multiple functions in one component.
3Ease of operation
If the electronics compartment is made accessible for maintenance, then ease of maintenance is improved, but the risk of moisture ingress and thermal exposure increases
Solution Approach 1:
The housing is divided into separate compartments: the first housing part contains the cell array and the second housing part contains the electronics. This segmentation allows the electronics to be accessed for maintenance through the removable first cover while the cell array remains protected in its sealed compartment.
Solution Approach 2:
The housing middle part serves as an intermediary that provides hermetic sealing and thermal isolation between the cell array and electronics compartments, allowing independent access to electronics while protecting them from harmful factors.
4Temperature
If a cooling system is integrated between housing parts, then cooling efficiency is improved, but the complexity of the housing structure increases
Solution Approach 1:
The cooling system is merged with the housing structure itself. The housing middle part, which connects the cell housing and electronics housing, is designed to provide thermal management functions, eliminating the need for separate cooling components and reducing overall complexity.
Solution Approach 2:
The housing middle part performs multiple functions: it provides structural connection between housing parts, enables hermetic sealing, and integrates the cooling system for the cell array. This multi-functionality reduces the number of separate components needed.
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 reduces material costs by integrating safety features, enhances crash and bollard protection, prevents moisture ingress, and ensures reliable operation by isolating electronics and cooling the cell pack, while allowing for servicing without opening the cell compartment.
Implementation Method 1
arranged between the two housing parts there is a housing middle part that separates the two housing parts horizontally and contains an interspace for a cooling fluid flowing through
Implementation Method 2
the cell pack is protected from damage in the event of lateral and longitudinal crash by an interspace, between it and the outer boundaries of the second housing part, which is at least partially reinforced by plasto-elastic material filling the interspaces
Implementation Method 3
the seal is designed to be burst-pressure resistant
Data Source
AI summary
An electric energy store for installing into a motor vehicle includes at least two housing parts. A first housing part is not designed to receive storage cells and a second housing part is designed to receive all of the storage cells. The first housing part is designed to be installed in the motor vehicle as an upper housing part, and the second housing part is designed to be installed in the motor vehicle as a lower housing part. The first housing part can be closed by a removable first cover, and the second housing part is designed as a closed capsule with a non-removable second cover.