Interlocking Cell Holder Tray for Battery Vent Sealing
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Solution Overview
Problem
Existing battery packs face challenges in locating battery cells on the cell holder, controlling potting resin leakage into vent channels, and ensuring a secure, watertight seal during assembly.
Innovation Solution
A cell holder tray with interlocking features, such as snap fits and chamfered walls, guides and mechanically locks battery cells into position, while adhesive and elastomer seals prevent potting from entering vent channels, forming a watertight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cell holding methods are used, then assembly is simple, but cell location precision and secure locking are insufficient
Solution Approach 1:
The cell holder tray is segmented into multiple interlocking features including protrusions, snap fits, and chamfered walls that work together to achieve precise cell location and secure locking. Each feature performs a specific function: protrusions guide cell position, chamfered walls provide alignment, and snap fits deliver mechanical locking.
Solution Approach 2:
The cell holder tray is pre-configured with interlocking features and sealing elements before cell assembly. The protrusions and chamfered walls are pre-formed to guide cell insertion, and the sealant is pre-applied to create watertight seals, enabling precise and secure assembly without requiring complex post-assembly adjustments.
2Reliability
If potting resin is applied for electrical isolation, then electrical isolation is achieved, but resin leakage into vent channels occurs
Solution Approach 1:
The harmful effect of potting resin leakage is prevented by extracting the sealing function from the potting process itself. A separate sealing system using elastomer rings and sealant is implemented around the vent channels, creating a barrier that prevents resin from entering the vent passages while maintaining electrical isolation functionality.
Solution Approach 2:
An elastomer ring and sealant act as intermediary elements between the potting resin and the vent channels. These sealing components create a protective barrier that allows the potting resin to be applied for electrical isolation without causing harmful leakage into the vent system.
3Strength
If mechanical interlocking features are added to secure cells, then cell positioning and locking are improved, but assembly complexity increases
Solution Approach 1:
Multiple functions are merged into a single integrated cell holder tray structure. The tray combines protrusions for positioning, chamfered walls for alignment, snap fits for mechanical locking, and sealing features for watertight seals. This integration achieves strong cell securing without proportionally increasing overall device complexity.
Solution Approach 2:
The interlocking features are designed to be self-actuating during assembly. The snap fits automatically engage with the cell holders when cells are inserted, providing mechanical locking without requiring additional fastening operations. The protrusions and chamfered walls self-align cells during insertion, reducing assembly complexity.
Data Source
AI summary
A rechargeable energy storage system includes a cell holder tray including a plurality of battery interlocking features, wherein the cell holder tray includes a plurality of vent passages through the cell holder tray and the cell holder tray includes a plurality of vent channels below the vent passages. A plurality of battery cells are each joined to a respective one of the battery interlocking features above one of the vent passages in the cell holder tray, wherein the plurality of battery cells are encapsulated in a polymer potting.