Battery Module Assembly With Potting Channels for Thermal Venting
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Solution Overview
Problem
Existing rechargeable energy storage devices face challenges in achieving efficient cell integration with both electrical and thermal systems within limited packaging dimensions, particularly in vehicles, requiring a hybrid orientation that balances electrical energy storage requirements and thermal management.
Innovation Solution
A multi-cell rechargeable energy storage system with vertically oriented cylindrical electrochemical battery cells arranged in modules, featuring a hybrid thermal and electrical design, including a serpentine busbar configuration, thermal management system with longitudinally oriented heat exchange plates, and a potting compound for structural integrity and pressure relief, along with a venting system for gas release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If vertically oriented cylindrical battery cells are arranged in modules with hybrid thermal and electrical design, then packaging efficiency and thermal management are improved, but device complexity increases
Solution Approach 1:
The battery system is divided into multiple cell modules, each containing vertically oriented cylindrical battery cells arranged in specific configurations. This segmentation allows for efficient space utilization while maintaining manageable complexity through modular design principles.
Solution Approach 2:
The patent combines thermal management channels and electrical busbars into a hybrid design where thermal channels serve both thermal management and structural functions, while busbars are integrated with cell holders. This merging reduces the number of separate components needed, improving packaging efficiency without proportionally increasing system complexity.
2Temperature
If thermal channels are formed between potting compound and bottom structure, then thermal management efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The bottom structure is pre-formed with integrated thermal channels before final assembly. The channels are created during bottom structure manufacturing, allowing thermal management pathways to be established in advance rather than requiring complex post-assembly operations to create thermal pathways.
Solution Approach 2:
The bottom structure serves multiple functions: it provides structural support, houses thermal management channels, and facilitates fluid distribution. This multi-functionality reduces the need for separate dedicated thermal management components, simplifying manufacturing while maintaining thermal efficiency.
3Reliability
If serpentine busbar configuration is used to connect cell modules, then electrical connectivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The busbars are configured in serpentine (curved) patterns rather than straight lines, allowing for flexible routing that accommodates manufacturing tolerances and cell position variations. This curved configuration provides natural compensation for alignment variations while maintaining reliable electrical connections between cell modules.
Solution Approach 2:
The serpentine configuration changes the geometric parameters of the busbar layout, transforming rigid straight-line connections into flexible curved paths. This parameter change allows the electrical connection system to accommodate variations in cell positioning while maintaining connection reliability.
4Strength
If potting compound encapsulates upper portions of battery cells, then structural integrity is improved, but pressure relief complexity increases
Solution Approach 1:
The potting compound acts as an intermediary material that provides structural support and encapsulation while incorporating integrated pressure relief pathways. These pathways are built into the potting compound structure itself, allowing gas venting without requiring separate complex pressure relief mechanisms.
Solution Approach 2:
The structural encapsulation function and pressure relief function are merged into a single integrated system. The potting compound provides both structural support and built-in venting channels, eliminating the need for separate pressure relief components and reducing overall system complexity.
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 system enables efficient packaging, thermal management, and mass reduction while ensuring safety through rapid thermal runaway detection and venting, maintaining structural integrity, and minimizing packaging complexity and cost.
Implementation Method 1
A multi-cell rechargeable energy storage system with vertically oriented cylindrical electrochemical battery cells arranged in modules, featuring a hybrid thermal and electrical design, including a serpentine busbar configuration, thermal management system with longitudinally oriented heat exchange plates, and a potting compound for structural integrity and pressure relief
Implementation Method 2
The vent is fluidly coupled to the plurality of channels via the header. Another aspect of the disclosure may include having each of the plurality of channels corresponding to one of the plurality of longitudinally oriented rows of the plurality of battery cells. Another aspect of the disclosure may include having each of the plurality of channels being formed between the potting compound that encapsulates the upper portions of the plurality of battery cells and the bottom structure of the enclosure, wherein the upper portion of each of the plurality of battery cells includes a cell vent for pressure relief
Implementation Method 3
A thermal management system includes first and second fluidic manifolds that are fluidly coupled to a plurality of longitudinally oriented heat exchange plates. The plurality of longitudinally oriented heat exchange plates are arranged to physically contact a portion of an outer surface of the plurality of battery cells
Implementation Method 4
A thermal management system includes first and second fluidic manifolds that are fluidly coupled to a plurality of longitudinally oriented heat exchange plates. The header is fluidly coupled to the plurality of channels, and the vent is fluidly coupled to the plurality of channels via the header
Data Source
AI summary
A method for assembling a rechargeable energy storage system includes assembling a plurality of cell modules into an upper structure of an enclosure, wherein the plurality of cell modules are composed of a plurality of battery cells and a plurality of collectors, wherein the plurality of collectors are arranged to electrically connect the battery cells; inverting the enclosure including the plurality of cell modules assembled therein; filling the enclosure with a liquified potting compound; curing the liquified potting compound to form a solidified potting compound; and assembling a bottom structure onto the upper structure of the enclosure to form a plurality of longitudinal channels.