Battery Cell Pack Interlayers for Swelling-Stable Sandwich Structures
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Solution Overview
Problem
Conventional battery designs for electric vehicles are complex and do not allow for 'cell-to-pack' integration with a sandwich structure, requiring a 'cell-to-module' arrangement and subsequent 'module-to-pack' integration, which complicates the design and does not effectively absorb the volume change of battery cells between charged and discharged states.
Innovation Solution
A battery cell pack with solid-state battery cells and a multiplicity of frame elements, where each battery cell is positioned between interlayers that compressively absorb the volume change, maintaining constant outer dimensions of the pack and enabling a stable, load-bearing sandwich structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional battery designs with cell-to-module arrangement are used, then structural stability is improved, but device complexity increases and cell volume change cannot be effectively absorbed
Solution Approach 1:
The patent divides the battery pack into direct cell-to-pack segments, eliminating the intermediate module layer. Each battery cell is directly mounted to the pack housing with cooling channels integrated into the housing structure, simplifying the overall architecture while maintaining structural stability through direct structural support.
Solution Approach 2:
The patent merges the housing structure with the cooling system by integrating cooling channels directly into the pack housing. This combination eliminates separate cooling components and simplifies the overall structure while maintaining both structural integrity and thermal management functionality.
2Device complexity
If battery cells are directly integrated into pack structure, then device complexity is reduced, but ability to absorb volume change during charge/discharge is worsened
Solution Approach 1:
The patent employs a flexible mounting structure where the cell holder or mounting brackets can elastically deform to accommodate cell expansion and contraction. This flexibility allows direct cell-to-pack integration while maintaining the ability to absorb volume changes during charge/discharge cycles without damaging the cells or structure.
Solution Approach 2:
The patent designs the mounting structure with adjustable parameters such as elastic deformation capacity, friction coefficients, and geometric configurations that allow it to adapt to cell volume changes. The structure transitions between rigid support and flexible accommodation based on the cell's expansion state.
3Use of energy by moving object
If solid-state battery cells are used, then specific energy density is improved, but operational reliability requirements become more stringent
Solution Approach 1:
The patent implements a self-regulating mounting system that automatically adjusts to cell expansion and contraction without external intervention. The elastic mounting structure self-compensates for volume changes, maintaining consistent contact pressure and electrical connections throughout charge/discharge cycles, thereby ensuring operational reliability.
Solution Approach 2:
The patent incorporates pre-designed elastic elements and compliance features in the mounting structure that anticipate and cushion against cell expansion forces before they can cause damage. This beforehand cushioning protects the solid-state cells from mechanical stress while maintaining reliable electrical connections.
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 configuration allows for a stable and efficient integration of battery cells in a sandwich structure, enhancing noise, vibration, and harshness quality, while providing a load-bearing capability and simplifying integration processes, with the interlayers ensuring uniform pressure distribution and preventing dendrite growth.
Implementation Method 1
The interlayer has a non-destructively elastically compressible form. Accordingly, the interlayer can be non-destructively elastically compressed by the battery cell in that the battery cell inserted in the battery cell space and thereby adjoining the one or more interlayers swells to a swollen size.
Implementation Method 2
the interlayers ensuring uniform pressure distribution and preventing dendrite growth
Data Source
AI summary
A battery cell pack includes a multiplicity of battery cells arranged next to one another. A multiplicity of frame elements corresponds geometrically to the battery cells. A battery cell is positionally fixed by means of two of the frame elements directly adjacent to each other by the corresponding battery cell being inserted into a battery cell space formed by the two directly adjacent frame elements. An intermediate layer is arranged directly between the respective battery cell and the frame elements, such that the respective battery cell is held in the battery cell space via the intermediate layer. The intermediate layer is elastically compressible, without destruction, by a swelling of the directly adjoining battery cell to a swelling extent, as a result of which, despite the swelling of the corresponding battery cell, a size of the battery cell space and therefore external dimensions of the battery cell pack remain constant.