Contoured Battery Case for Irregular Cells
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Solution Overview
Problem
Existing battery cases face challenges in achieving high volumetric packaging efficiency and reducing thermal resistance, particularly with irregular and curvilinear shapes, leading to increased bulk, weight, and reduced lifespan due to heat generation.
Innovation Solution
The battery case features interconnected cell housings made of heat conductive materials with contoured internal surfaces to match the shape of electrochemical cells, enclosing their outer surfaces and incorporating heat conductive filler materials within the case, along with an electronic component housing that minimizes extraneous volumes and enhances heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional battery cases are used with irregular and curvilinear cells, then the battery can accommodate various cell shapes, but volumetric packaging efficiency decreases
Solution Approach 1:
The battery case is divided into multiple contoured cell holders, each specifically shaped to accommodate different cell geometries. This segmentation allows each holder to tightly fit its designated cell type while maintaining overall case efficiency.
Solution Approach 2:
Different regions of the battery case are designed with locally optimized geometries - each cell holder has contours matched to specific cell shapes (cylindrical, prismatic, irregular). This local customization maximizes space utilization for each cell type without compromising overall packaging efficiency.
2Adaptability or versatility
If conventional battery cases are used with irregular and curvilinear cells, then the battery can accommodate various cell shapes, but the overall bulk increases
Solution Approach 1:
The battery case is divided into multiple contoured cell holders, each specifically shaped to accommodate different cell geometries. This segmentation allows each holder to tightly fit its designated cell type while maintaining overall case efficiency.
Solution Approach 2:
Different regions of the battery case are designed with locally optimized geometries - each cell holder has contours matched to specific cell shapes (cylindrical, prismatic, irregular). This local customization maximizes space utilization for each cell type without compromising overall packaging efficiency.
3Ease of manufacture
If conventional battery cases are used, then manufacturing is simpler, but thermal resistance increases leading to reduced battery lifespan
Solution Approach 1:
The cell holders are designed with varying wall thicknesses and material compositions tailored to local thermal requirements. Areas with higher heat generation have enhanced thermal conduction features, while other regions maintain standard construction for manufacturing efficiency.
Solution Approach 2:
The battery case incorporates materials with different thermal conductivities in specific regions - high thermal conductivity materials in areas requiring heat dissipation, and standard materials elsewhere. This composite approach optimizes thermal management while maintaining manufacturing feasibility.
4Device complexity
If conventional battery cases are used, then device complexity is lower, but heat dissipation is insufficient leading to safety issues
Solution Approach 1:
The cell holders are designed with varying wall thicknesses and material compositions tailored to local thermal requirements. Areas with higher heat generation have enhanced thermal conduction features, while other regions maintain standard construction for manufacturing efficiency.
Solution Approach 2:
The battery case incorporates materials with different thermal conductivities in specific regions - high thermal conductivity materials in areas requiring heat dissipation, and standard materials elsewhere. This composite approach optimizes thermal management while maintaining manufacturing feasibility.
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 design improves volumetric packaging efficiency, reduces weight, and extends battery lifespan by effectively dissipating heat, making it safer and more versatile for various applications.
Implementation Method 1
The external surfaces of the cell housings define a plurality of interior volumes that are external to each of the cell housings and internal to an outer periphery of the battery case, and wherein at least one of the interior volumes houses a heat conductive filler material
Data Source
Figure 1A~3
Figure 4~6
Figure 7A~8
AI summary
A battery case (1) houses a battery with a plurality of non-prismatic electrochemical cells and at least one electronic component. The battery case includes a plurality of cell housings (12) and at least one electronic component housing (18) that accommodates the at least one electronic component. The plurality of cell housings each define an internal space (11) sized to accommodate one of the electrochemical cells, and include an internal surface (16) at least a portion of which is shaped to substantially correspond to a non-prismatic exterior surface (22) of the one of the electrochemical cells to be housed by the cell housing, and an external surface at least a portion of which follows contours of a corresponding portion of the inner surface.