Traction Battery Pack Assembly With Sandwiched Thermal Barrier
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Solution Overview
Problem
The assembly of traction battery packs faces challenges in securely positioning and aligning pouch cells, particularly in containing thermal energy and vent byproducts, which can lead to misalignment and inefficient use of thermal interface materials.
Innovation Solution
The method involves securing battery cells to either side of a thermal barrier, which is sandwiched between them, using adhesive tape, and positioning this subassembly within a battery pack enclosure, with the thermal barrier extending vertically to contact the underside of the enclosure, facilitating alignment and containment of thermal energy and vent byproducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pouch cells are secured using conventional methods inside the battery pack enclosure, then the cells can be positioned, but misalignment occurs and thermal energy containment is insufficient
Solution Approach 1:
The thermal barrier is pre-attached to the enclosure before inserting the battery cells. This preliminary action establishes a fixed reference structure that guides cell placement and ensures proper alignment, while simultaneously providing thermal containment from the outset
Solution Approach 2:
The thermal barrier serves as an intermediary component between the enclosure and the battery cells. It mediates both the mechanical alignment function and the thermal containment function, resolving the contradiction by providing a single structure that fulfills both requirements
2Object-affected harmful factors
If thermal interface materials are used extensively to contain thermal energy, then thermal containment improves, but material usage and complexity increase
Solution Approach 1:
The thermal barrier is extracted from the category of consumable thermal interface materials and transformed into a permanent structural component of the enclosure. This extraction eliminates the need for additional thermal interface materials while maintaining thermal containment functionality
Solution Approach 2:
The thermal barrier is designed to perform multiple functions simultaneously: it provides thermal containment, structural support, and alignment guidance. This multi-functionality eliminates the need for separate thermal interface materials, reducing material usage while maintaining effectiveness
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 approach enhances the securement and alignment of battery cells, reduces thermal interface material usage, and effectively contains thermal energy and vent byproducts, improving the assembly process and pack performance.
Implementation Method 1
securing the at least one first battery cell to the first side and securing the at least one second battery cell to the second side using an adhesive tape
Implementation Method 2
containing thermal energy and vent byproducts
Data Source
AI summary
A method of assembling a battery pack includes, outside of a battery pack enclosure, securing at least one first battery cell to a first side of a thermal barrier, and securing at least one second battery cell to an opposite, second side of the thermal barrier. The method provides a battery cell subassembly with the thermal barrier sandwiched between the at least one first battery cell and the at least one second battery cell.