Cell Holder Tray Circuits for Compact EV Battery Isolation
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Solution Overview
Problem
Existing vehicle battery assemblies face challenges in efficiently connecting multiple battery cells while minimizing the use of electrical isolation layers and adhesives, which can increase assembly height, volume, and complexity, and do not adequately address thermal runaway conditions.
Innovation Solution
Incorporating electrical circuits within the cell holder tray, using dielectric coatings and integrally threaded features, and employing over molding or heat staking to connect battery cells in series or parallel configurations, reducing the need for additional isolation layers and adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional electrical connection methods with isolation layers and adhesives are used, then electrical connections between battery cells can be established, but assembly height and volume increase and energy density decreases
Solution Approach 1:
The electrical circuit is integrated directly into the cell holder tray structure, merging the electrical connection function with the mechanical support function. This eliminates the need for separate isolation layers and adhesives, reducing assembly volume and increasing energy density by approximately 7.5%.
Solution Approach 2:
The cell holder tray is designed to serve multiple functions simultaneously: mechanical support for battery cells, electrical connection through embedded circuits, and thermal management. This multi-functionality reduces the number of separate components needed, thereby reducing overall assembly volume.
2Reliability
If traditional electrical connection methods with multiple isolation layers are used, then electrical isolation during thermal runaway is provided, but assembly complexity and manufacturing steps increase
Solution Approach 1:
The electrical circuit is embedded directly into the cell holder tray, merging the electrical connection and isolation functions into a single integrated component. This eliminates multiple separate isolation layers and reduces assembly complexity while maintaining reliability during thermal runaway conditions.
Solution Approach 2:
The cell holder tray is constructed from composite materials that provide both mechanical strength and electrical insulation properties. This allows the tray to serve as both a structural support and an electrical isolation barrier, reducing the need for additional isolation layers.
3Reliability
If multiple isolation layers and adhesives are used for electrical connections, then electrical isolation is achieved, but assembly height increases
Solution Approach 1:
The electrical circuit is integrated into the cell holder tray structure, eliminating the need for multiple separate isolation layers and adhesives. This integration reduces assembly height while maintaining electrical isolation through the tray's inherent insulating properties and the circuit's design.
4Ease of manufacture
If traditional connection methods with multiple adhesives and isolation layers are used, then battery cells can be connected, but manufacturing time and production complexity increase
Solution Approach 1:
The electrical circuit is embedded into the cell holder tray as an integrated component, eliminating the need for multiple separate assembly steps involving adhesives and isolation layers. This integration simplifies the manufacturing process and reduces assembly time.
Solution Approach 2:
The electrical circuit is pre-integrated into the cell holder tray during tray manufacturing, so that when battery cells are installed, electrical connections are already in place. This preliminary action eliminates subsequent connection steps and reduces overall manufacturing time.
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
This approach enhances energy density, reduces assembly height and volume by up to 7.5%, eliminates unnecessary isolation layers and adhesives, and provides electrical insulation during thermal runaway conditions.
Implementation Method 1
the electrical circuit includes a dielectric coating configured to electrically insulate the electrical circuit during a thermal runaway condition of the multiple rechargeable battery cells
Implementation Method 2
the multiple rechargeable battery cells are coupled with the cell holder tray via at least one of an adhesive, a snap fit, and a threaded screw
Data Source
AI summary
An example vehicle battery assembly includes multiple rechargeable battery cells configured to supply power to a drive unit of a vehicle, a cell holder tray mounted within the vehicle, the cell holder tray configured to support the multiple rechargeable battery cells, an upper shear plate, wherein the multiple rechargeable battery cells are between the upper shear plate and the cell holder tray, and an electrical circuit within the cell holder tray, the electrical circuit electrically connected between at least two of the multiple rechargeable battery cells.