Battery Pressure Management Assembly for Swelling Control
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Solution Overview
Problem
Existing battery technologies fail to efficiently manage pressure and mechanical stress on batteries, resulting in capacity fading and impedance growth, and dimensional instability over product life.
Innovation Solution
A method for manufacturing a battery with a pressure management device comprising a substrate, adhesive layer, foam and/or elastomer insulation, and cover to manage battery pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a battery pack is designed with a maximum well budget (void space) to accommodate battery swelling, then the battery can freely expand and accommodate mechanical movements, but the battery experiences capacity fading, impedance growth, and dimensional instability due to unmanaged pressure
Solution Approach 1:
A pressure management device is introduced as an intermediary component between the battery pack and the enclosure. This device includes a compressible material (foam or elastomer) that mediates the interaction between the expanding battery and the rigid enclosure, providing controlled resistance to swelling while maintaining adaptability
Solution Approach 2:
The pressure management device changes the physical parameters within the battery enclosure by introducing a compressible material that can dynamically adjust its compression force. This allows the system to maintain optimal pressure conditions that prevent capacity fading and impedance growth while still accommodating necessary swelling
2Strength
If the battery enclosure is made rigid to provide structural support, then the battery is protected from external mechanical damage, but the battery experiences dimensional instability and performance degradation due to restricted pressure management
Solution Approach 1:
The pressure management device incorporates flexible compressible materials (foam or elastomer) that can deform and adapt to battery dimensional changes. These flexible elements provide a compliant interface between the rigid enclosure and the battery, allowing the enclosure to maintain its protective strength while the flexible material accommodates dimensional instability through controlled compression
3Volume of stationary object
If void space is increased to allow battery free expansion, then the battery can accommodate swelling and mechanical movements, but the battery suffers from capacity fading and impedance growth due to lack of pressure management
Solution Approach 1:
The compressible pressure management device serves as a mediator that fills the void space while providing controlled resistance to battery expansion. Rather than leaving empty void space that allows uncontrolled swelling, the compressible material provides gentle, distributed pressure that maintains battery capacity and prevents impedance growth while still accommodating necessary dimensional changes
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 effectively reduces capacity fading, impedance growth, and dimensional instability, enhancing battery performance and reliability.
Implementation Method 1
foam and/or elastomer insulation compressed around at least a portion of the battery pack
Implementation Method 2
an adhesive layer that attaches the battery back to the substrate
Data Source
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AI summary
In this disclosure, a battery pack/module with pressure control device integrated has been introduced to provide more efficient packing in system. This design reduces and deaccelerates fading/aging, impedance growth, and dimensional instability over product life. Moreover, it also helps protect the battery from damage with improved reliability. This technology enables better industrial design, e.g., for XR and wearable systems.