Deformable Cell Holder Seals for Battery Potting Leakage
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Solution Overview
Problem
The challenge in battery modules is preventing potting material leakage during the curing process, which can disrupt the structural integrity and cooling systems of densely packed battery cells.
Innovation Solution
A cell holder design featuring deformable members within the through openings that protrude perpendicularly to reduce the opening diameter, supporting the potting material and preventing leakage by maintaining contact with the battery cells during insertion and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the through opening diameter is reduced to prevent potting leakage, then potting material leakage is prevented, but battery cell insertion becomes more difficult
Solution Approach 1:
The cell holder incorporates a deformable member that can dynamically change the through opening diameter. During insertion, the opening is larger to accommodate the battery cell. During potting, the deformable member is pressed against the battery cell to reduce the opening diameter and prevent potting material leakage. This dynamic adjustment resolves the contradiction between insertion ease and leakage prevention.
2Reliability
If deformable members are added to reduce through opening diameter, then potting leakage is prevented, but device complexity increases
Solution Approach 1:
The cell holder uses a deformable member made of flexible material that can elastically deform to adjust the through opening diameter. This flexible component prevents potting leakage without requiring complex mechanical adjustment mechanisms, thereby limiting the increase in device complexity while achieving the desired leakage prevention.
3Reliability
If the through opening diameter is reduced, then cooling channel integrity is maintained, but manufacturing precision requirements increase
Solution Approach 1:
Rather than manufacturing the through opening with a fixed small diameter that would require high precision, the cell holder uses a deformable member to dynamically reduce the opening diameter only when needed for potting. This approach maintains larger, easier-to-manufacture openings while still protecting cooling channel integrity during the potting process.
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 deformable members effectively prevent potting material leakage, ensuring stable cell positioning and maintaining the integrity of the cooling channels within the battery module.
Implementation Method 1
in each through opening a deformable member is protruding in the through opening in a direction which is perpendicular to the direction of extension of the through opening to thereby decrease the diameter of the through opening
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
A cell holder for holding a plurality of battery cells, said cell holder comprising a body, said body having an upper surface, a lower surface, and a plurality of through openings, wherein each through opening extends between the upper surface and the lower surface and is arranged to receive a battery cell, wherein in each through opening a deformable member is protruding in the through opening in a direction which is perpendicular to the direction of extension of the through opening to thereby decrease the diameter of the through opening such that the diameter of the through opening in the plane in which the deformable member is protruding is smaller than the outer diameter of the battery cell.