Cell-to-Pack Battery Housing With Venting Frame for Thermal Events
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Solution Overview
Problem
Existing battery packs face challenges in energy density due to space inefficiencies and are vulnerable to thermal events, which can lead to fire or explosion, especially in densely packed configurations used in electric vehicles.
Innovation Solution
A battery pack design that directly receives battery cells without intermediate modules, using a cell case with a metal cover and insulation block to vent gases efficiently and a venting frame to manage thermal events, enhancing safety and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are densely packed in a modular configuration with module cases and frames, then the battery pack can be assembled systematically, but the energy density decreases due to space occupied by structural components and assembly tolerances
Solution Approach 1:
The battery pack is divided into multiple battery cell groups, where each group consists of a specific number of battery cells arranged in a defined configuration. This segmentation allows for systematic assembly while optimizing the space utilization within each group, thereby improving energy density without compromising manufacturing ease.
Solution Approach 2:
Adjacent battery cell groups are coupled together to form integrated battery cell assemblies. By merging multiple groups into unified assemblies with shared structural components, the patent reduces redundant structural elements and assembly interfaces, thereby increasing the proportion of space available for active battery cells and improving overall energy density.
2Adaptability or versatility
If a modular battery pack design with multiple module cases is used, then the battery pack can accommodate various configurations, but the device complexity increases due to multiple structural components
Solution Approach 1:
The battery cell groups are designed with standardized configurations and coupling mechanisms that can be universally applied across different battery pack sizes and applications. This universality allows the same basic building block to be adapted for various configurations, reducing the need for multiple specialized components and thereby simplifying the overall device complexity.
Solution Approach 2:
Battery cell groups are nested within larger battery cell assemblies through a hierarchical structure where smaller units are integrated into larger units. This nesting approach allows for scalable configurations where the same modular unit can be repeated and combined in different quantities to achieve various pack sizes, maintaining configuration flexibility while reducing structural complexity through standardized nesting patterns.
3Strength
If battery cells are double-cased in modular assemblies, then the cells are protected structurally, but heat dissipation efficiency decreases due to reduced thermal contact with cooling structures
Solution Approach 1:
The patent extracts the thermal management function from the modular battery cell assembly structure and implements it at the battery cell group level. By providing cooling structures that directly contact each battery cell group rather than requiring heat to traverse multiple module boundaries, the design maintains structural protection while significantly improving heat dissipation efficiency through reduced thermal resistance paths.
Data Source
AI summary
A battery pack has structure for improving energy density and enhancing safety against a thermal event in a battery cell or a cell assembly. The battery pack includes a cell assembly including n battery cells where n is a natural number of 1 or greater; a cell case accommodating the cell assembly; and a pack housing having an internal space in which the at least one cell case is received.