EV Low Voltage Battery Housing with Desiccant and Pressure Valve
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Solution Overview
Problem
Traditional low voltage automotive batteries for electric vehicles are often lead-acid and require fluid-filled containers, which can be cumbersome and prone to moisture and pressure issues, and lack efficient manufacturing processes.
Innovation Solution
A low voltage battery design featuring a housing with a top and bottom portion, containing rechargeable electrochemical cells, a printed circuit board, and a bus bar, with a desiccant and two-way pressure valve to prevent moisture ingress and pressure equilibration, allowing for a hermetic seal and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lead-acid battery design with fluid-filled containers is used, then the battery can provide power for starting and electric systems, but the design becomes cumbersome and prone to moisture and pressure issues
Solution Approach 1:
The patent removes the fluid-filled container entirely from the battery design, extracting the problematic element that caused moisture and pressure issues. The electrolyte is contained within sealed individual cell structures rather than a shared fluid container, eliminating the need for complex fluid containment housing.
Solution Approach 2:
The battery is divided into multiple individual cell structures, each with its own housing and electrolyte containment. This segmentation allows each cell to be independently sealed and managed, simplifying the overall housing structure while improving reliability by isolating potential failure points.
2Ease of manufacture
If traditional battery manufacturing processes are used, then the battery can be produced with established methods, but the manufacturing becomes expensive and complex
Solution Approach 1:
The individual cell structures are pre-assembled and pre-sealed as complete units before final battery assembly. This preliminary action allows for standardized manufacturing of cell modules that can be quickly integrated into the final battery pack, improving both ease of manufacture and productivity.
Solution Approach 2:
Multiple functional components (cell structure, electrolyte containment, sealing elements) are merged into integrated cell modules. This consolidation reduces the number of separate manufacturing steps and assembly operations, lowering costs while improving assembly efficiency.
3Object-affected harmful factors
If the housing is sealed to prevent moisture ingress, then moisture protection is improved, but pressure equilibration becomes problematic
Solution Approach 1:
The sealing approach varies by location: critical areas have hermetic seals to prevent moisture ingress, while specific pressure equalization ports allow controlled pressure communication with the external environment. This local differentiation of sealing quality resolves the contradiction between moisture protection and pressure equilibration.
4Reliability
If individual cell monitoring is implemented, then reliability and efficiency improve, but device complexity increases
Solution Approach 1:
The circuit board performs multiple functions: it provides structural support, enables electrical connections between cells, and implements monitoring capabilities. This multi-functionality reduces the need for separate dedicated monitoring components, minimizing the increase in device complexity while maintaining reliability benefits.
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 provides a smart, fluid-free rechargeable battery that is easier and less expensive to manufacture, with enhanced protection against moisture and pressure, and allows for individual cell monitoring, improving reliability and efficiency.
Implementation Method 1
The housing can includes a desiccant and/or a two-way pressure valve extending through a surface of the housing
Implementation Method 2
The valve may be used to prevent moisture ingress into an interior of the housing and/or may allow a pressure inside of the housing to equilibrate to the external air pressure
Implementation Method 3
A plurality of rechargeable electrochemical cells may be disposed within the bottom portion
Implementation Method 4
allowing for a hermetic seal and simplified assembly
Data Source
AI summary
A battery for an electric vehicle is disclosed. The battery may be a low voltage battery for powering low voltage systems. The battery may include a housing formed from at least two parts. For example, the housing may include a top portion that is sealed to a bottom portion. A plurality of rechargeable electrochemical cells may be disposed within the bottom portion. A printed circuit board and/or a bus bar may be disposed within the top portion. The housing can includes a desiccant and/or a two-way pressure valve extending through a surface of the housing. The valve may be used to prevent moisture ingress into an interior of the housing and/or may allow a pressure inside of the housing to equilibrate to the external air pressure.