Multifunctional Cross-Member Beams for Battery Pack Venting
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Solution Overview
Problem
Current traction battery packs face challenges in effectively interfacing and supporting various subcomponents of the cell stack, particularly in managing thermal events and ensuring structural integrity, while also facilitating efficient venting of battery cell byproducts.
Innovation Solution
The use of multifunctional cross-member beams that support battery cells, thermal barriers, and bus bars, while incorporating features for venting passageways and structural reinforcement, such as pultrusion sections and vent openings, to manage thermal events and maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional single-function cross-member beams are used, then the structure is simple, but the ability to support multiple subcomponents and manage thermal events is insufficient
Solution Approach 1:
The cross-member beam is designed to perform multiple functions simultaneously: providing structural support for battery cells, incorporating venting features for thermal event management, and creating pathways for byproduct evacuation. This multi-functional design resolves the contradiction by enabling a single component to support various subcomponents while maintaining structural integrity and thermal safety.
Solution Approach 2:
The invention merges the structural support function with thermal management and venting functions into a single integrated cross-member beam structure. By combining these previously separate functions into one component, the design achieves versatility without proportionally increasing overall system complexity.
2Reliability
If traditional cross-member beams without venting features are used, then the manufacturing is simpler, but the ability to vent battery cell byproducts during thermal events is insufficient
Solution Approach 1:
The cross-member beam incorporates segmented venting features including vent openings and venting passageways that divide the thermal management function into discrete pathways. This segmentation allows byproducts to be channeled through specific routes while maintaining the overall structural integrity and simplifying the manufacturing process compared to fully integrated complex venting systems.
3Strength
If cross-member beams with reinforcement sections are used, then the structural integrity is improved, but the weight of the component increases
Solution Approach 1:
The cross-member beam incorporates reinforcement sections that appear to use composite material structures, combining different material properties to achieve enhanced structural integrity. The reinforcement sections provide additional strength and stiffness while the pultrusion manufacturing process optimizes the material distribution to minimize unnecessary weight.
4Productivity
If multiple cell tab terminals overlap through the same cross-member beam, then the electrical connection efficiency is improved, but the risk of thermal propagation between cells increases
Solution Approach 1:
The cross-member beam acts as an intermediary structure between overlapping cell tab terminals. By providing a controlled interface with backing tabs and designated contact areas, the beam enables efficient electrical connections while maintaining physical separation and preventing direct thermal propagation pathways between adjacent battery cells.
Data Source
AI summary
Multifunctional cross-member beams are provided for use within traction battery packs. An exemplary cross-member beam may include features for interfacing with and supporting various subcomponents (e.g., battery cells, cell tab terminals, bus bars, thermal barriers, etc.) of a cell stack of the traction battery pack. The cross-member beam may further incorporate features for facilitating the venting of battery cell vent byproducts during battery thermal events.