Extruded Battery Case With Integrated Alignment And Cooling Conduits
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Solution Overview
Problem
Conventional battery packs for electrified vehicles face challenges in aligning and retaining battery assemblies while efficiently managing temperature, often requiring separate spacers and complex tooling for structural integrity and fluid flow.
Innovation Solution
The use of an extruded case with integrated alignment and conduit features that interface with other portions of the battery pack to limit movement, facilitate temperature management fluid flow, and enhance structural integrity, reducing the need for discrete spacers and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate spacers and complex tooling are used for structural integrity and fluid flow, then temperature management and alignment are improved, but device complexity and part counts increase
Solution Approach 1:
The patent combines multiple separate components (battery case, alignment features, conduit features, and spacers) into a single integrated extruded case. The extruded case includes built-in alignment features that interface with other battery pack portions to limit movement, and conduit features that carry temperature management fluid, eliminating the need for discrete spacers and reducing overall part counts while maintaining structural integrity and temperature management functionality
2Manufacturing precision
If separate spacers and complex tooling are used for structural integrity and fluid flow, then alignment and retention of battery assemblies are improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent integrates alignment features directly into the extruded case structure, eliminating the need for separate spacers and complex assembly tooling. The extruded case is designed with built-in features that provide precise alignment and retention of battery assemblies through a simplified assembly process
Solution Approach 2:
The extruded case serves multiple functions simultaneously: it provides structural support, enables precise alignment through integrated alignment features, and facilitates fluid flow through built-in conduit features. This multi-functionality reduces the need for separate specialized components and simplifies the overall manufacturing process
3Strength
If conventional battery pack design is used, then structural integrity is maintained, but temperature management efficiency deteriorates
Solution Approach 1:
The patent merges the structural case with integrated conduit features into a single extruded component. The conduit features are built into the extruded case structure, allowing temperature management fluid to flow directly through the battery pack while the case simultaneously provides structural support and alignment functions, improving temperature management efficiency without compromising structural integrity
Data Source
AI summary
An exemplary battery cell assembly includes, among other things, an extruded case that provides an open area, and an electrode of a battery pack of an electrified vehicle. The electrode is held within the open area. An exemplary electrode housing method includes, among other things, positioning an electrode of an electrified vehicle battery pack within an open area of an extruded case.