Multi-Function Structural Assembly for Battery Cell Retention

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Solution Overview

Problem

Conventional battery assemblies for electrified vehicles require multiple components for retention and thermal management, leading to increased complexity and air volume, while also relying on threaded fasteners and array retention components.

Innovation Solution

A multi-function structural assembly that encloses and thermally conditions battery cell stacks by applying a compressive load and using channels for fluid communication, reducing the number and size of components and eliminating threaded fasteners, resulting in a near zero air volume design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate components (enclosure assembly, array structure, cold plate) are used for retention and thermal management, then the battery cells are properly retained and thermally managed, but the device complexity and air volume increase

Engineering Contradiction:

Improvebattery cell retention and thermal managementVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the enclosure assembly, array structure, and cold plate into a single integrated structural assembly. The structural assembly includes walls that form pockets for receiving cell stacks, with thermal management channels integrated into the walls. This merging eliminates the need for separate components while maintaining all necessary functions of retention and thermal management.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The structural assembly performs multiple functions simultaneously: it provides structural support, retains battery cells through pockets, enables thermal management through integrated channels, and eliminates the need for separate fasteners. This multi-functionality reduces overall device complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

Engineering Contradiction:

Improvebattery cell retention and thermal managementVSAvoidair volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The integration of multiple components into a single structural assembly eliminates the air gaps and interfaces between separate parts. The structural assembly's walls directly form pockets for cell stacks with thermal channels, removing the need for separate enclosure assemblies, array structures, and cold plates that would otherwise occupy additional volume.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If threaded fasteners and array retention components are used, then the battery cells are securely retained, but the device complexity increases

Engineering Contradiction:

Improvebattery cell retentionVSAvoidnumber of fasteners and retention components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The structural assembly integrates retention functionality directly into its walls through the pocket structure. The walls themselves provide the retention mechanism, eliminating the need for separate threaded fasteners and array retention components. This reduces device complexity while maintaining secure cell retention.

Inventive Principle:

Principle #5Merging (Combining)

4Volume of moving object

If a compact design with reduced air volume is implemented, then the packaging efficiency is improved, but the thermal management capability may be compromised

Engineering Contradiction:

Improveair volumeVSAvoidthermal management capability

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The structural assembly walls serve dual purposes: they provide structural boundaries for pockets and simultaneously contain integrated thermal management channels. This allows effective thermal management within a compact volume by utilizing the wall structure itself for fluid communication, rather than requiring separate thermal management components that would increase air volume.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 provides a compact, efficient battery assembly with reduced air volume, improved thermal management, and simplified packaging, enhancing the reliability and performance of electrified vehicle powertrains.

Implementation Method 1

The structural assembly is configured to assert a compressive load on the first cell stack

Methodology Applied

Scientific EffectCompressive load: Compression

Implementation Method 2

at least one of the plurality of walls includes a channel configured to communicate a fluid to thermally condition the plurality of battery cells

Methodology Applied

Scientific EffectThermal conditioning: Cooling

Data Source

PatentUS11695171B2Battery assembly with multi-function structural assembly

Publication Date: 2023.07.04 FORD GLOBAL TECH LLC

AI summary

A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a first cell stack including a plurality of battery cells and a structural assembly including a first pocket sized and shaped to receive the first cell stack. The structural assembly is configured to assert a compressive load on the first cell stack and at least partially enclose the first cell stack.