Battery Module Housing for Dense Cell Stacking and Thermal Safety
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Solution Overview
Problem
Existing battery devices are complex and costly to produce, lacking efficient designs that optimize space utilization, thermal management, and safety features.
Innovation Solution
A battery device comprising self-supporting battery modules with a frame element and base element forming a pot-shaped receiving space for battery cells, allowing parallel stacking, and featuring integrated temperature control, degassing, and propagation protection, with components made from materials like aluminum and plastic to reduce costs and enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional battery device designs are used, then structural stability is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The battery device is divided into modular battery modules, each containing a specific number of battery cells (e.g., 50-600 cells per module). These modules can be stacked in series to achieve the desired total capacity while maintaining structural integrity. The frame element and base element are segmented components that can be independently manufactured and assembled.
Solution Approach 2:
The frame element serves multiple functions: it provides structural support, defines the receiving space for battery cells, and contributes to the overall device housing. The base element similarly serves as both a structural component and a mounting surface for securing battery modules together, reducing the need for separate specialized components.
2Quantity of substance
If more battery cells are packed into each module, then energy storage capacity increases, but space utilization and thermal management become more difficult
Solution Approach 1:
Battery cells are arranged in a nested configuration within the receiving space defined by the frame and base elements. The cells are positioned to maximize volumetric efficiency while maintaining access for thermal management pathways. Multiple layers of cells can be stacked vertically within the same footprint.
Solution Approach 2:
The patent transitions from two-dimensional cell arrangement to three-dimensional stacking configurations. Battery modules can be stacked vertically in series, utilizing the vertical dimension to increase capacity without expanding the horizontal footprint. This allows efficient use of available space while maintaining thermal management pathways between stacked modules.
3Quantity of substance
If battery modules are stacked in series, then energy storage capacity increases, but manufacturing and assembly complexity increase
Solution Approach 1:
The battery device is divided into standardized battery modules that can be independently manufactured, tested, and assembled. Each module contains a defined number of battery cells (e.g., 50-600 cells) and can be stacked in series to achieve the desired total capacity. This modular approach simplifies manufacturing by allowing parallel production of multiple identical modules.
Solution Approach 2:
Battery modules are pre-assembled and pre-tested as complete functional units before being stacked together to form the final battery device. The frame and base elements are pre-configured with appropriate receiving spaces and mounting features, allowing rapid assembly of multiple modules without requiring complex on-site configuration.
4Ease of manufacture
If frame elements form the outer housing, then manufacturing cost decreases, but protection and sealing requirements increase
Solution Approach 1:
The frame element serves dual purposes as both the structural support framework and the outer housing protection. It is designed with integrated sealing features and mounting points that provide environmental protection while maintaining structural integrity. The base element similarly provides both structural support and sealing surfaces for battery module interfaces.
Solution Approach 2:
The frame and base elements can be constructed from composite materials or material combinations that provide both structural strength and environmental resistance. This allows the same components to fulfill multiple functions including mechanical support, sealing, and protection against environmental factors without requiring additional specialized layers.
Data Source
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AI summary
The invention relates to a battery device which is simple and economical to produce. Said battery device comprises one or more battery modules wherein one of the respective battery modules comprises the following: a frame element, a base element and a plurality of battery cells.