Battery Cell Test Fixture With Thermal and Structural Module Simulation
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Solution Overview
Problem
Existing secondary battery testing apparatuses lack the accuracy and reliability needed to effectively evaluate the state of charge, power output, durability, and lifetime of secondary batteries, particularly in simulating the thermal and structural properties of battery modules.
Innovation Solution
A method of manufacturing a cell test apparatus that involves determining the thickness of a thermal-insulation layer and outer wall by analyzing heat and stress distribution in a battery module, using materials like Bakelite and stainless steel to enhance the simulation accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the cell test apparatus uses a simple structure without detailed thermal-insulation layer and outer wall design, then the device complexity is reduced, but the measurement precision and reliability of battery module simulation deteriorate
Solution Approach 1:
The patent applies the copying principle by replicating the thermal and structural characteristics of an actual battery module in a simplified test apparatus. The thermal-insulation layer thickness is determined by analyzing heat generation from a battery module, and the outer wall thickness is determined by analyzing the module structure, creating a scaled or simplified copy that preserves essential thermal and structural properties for accurate testing without requiring a full-scale battery module
Solution Approach 2:
The patent applies local quality by providing different thickness specifications for different parts of the test apparatus. The thermal-insulation layer has a specific thickness determined by thermal analysis, while the outer wall has a different thickness determined by structural analysis, allowing each component to be optimized for its specific function rather than using a uniform structure throughout
2Reliability
If the thermal-insulation layer thickness is determined without analyzing heat generation from battery module, then the manufacturing process is simplified, but the reliability of test results deteriorates
Solution Approach 1:
The patent applies preliminary action by performing thermal analysis and structural analysis before manufacturing the test apparatus. The thickness of the thermal-insulation layer is determined by analyzing heat generation from a battery module in advance, and the outer wall thickness is determined by analyzing the module structure beforehand, ensuring that the apparatus is designed with correct specifications before production begins
Solution Approach 2:
The patent replaces empirical or mechanical trial-and-error methods with thermal analysis and structural analysis to determine component dimensions. Instead of relying on experience or simple mechanical considerations, the design uses analytical methods to calculate the appropriate thickness values for the thermal-insulation layer and outer wall, improving reliability while maintaining manufacturing feasibility
3Measurement precision
If the outer wall thickness is determined without analyzing battery module structure, then the manufacturing process is simplified, but the simulation accuracy of battery module deteriorates
Solution Approach 1:
The patent applies preliminary action by performing structural analysis of the battery module before manufacturing the test apparatus. The outer wall thickness is determined by analyzing the battery module structure in advance, ensuring that the structural characteristics are captured in the design phase rather than requiring complex manufacturing adjustments later
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 method improves the accuracy and reliability of the cell test apparatus by aligning the thermal and structural properties with those of actual battery modules, resulting in more precise lifetime and performance evaluations.
Implementation Method 1
determining a thickness of a thermal-insulation layer of the cell test apparatus by analyzing heat generated from a battery module including a plurality of cells
Implementation Method 2
determining a thickness of an outer wall of the cell test apparatus by analyzing a structure of the battery module
Data Source
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AI summary
A method of manufacturing a cell test apparatus, the method comprising, determining by analyzing heat generated from a battery module including a plurality of cells, a thickness of a thermal-insulation layer of the cell test apparatus simulating the battery module and including one or more target cells therein, determining by analyzing a structure of the battery module, a thickness of an outer wall of the cell test apparatus; and determining a length of a spacer of the cell test apparatus.