Extruded Energy Storage Housing for Scalable Battery Pack Assembly
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Solution Overview
Problem
Existing energy storage housings made of sheet metal require redesign and costly tooling changes when the number of battery cell packs changes, leading to increased costs and complexity.
Innovation Solution
A housing for energy storage with an extruded portion that can be adjusted in length during the manufacturing process, allowing for flexible adaptation to different numbers of components and voltage, energy, and power demands, using a process that integrates fastening elements and heat management surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sheet metal housings are used for energy storage, then the housing provides structural strength and protection, but redesign and tooling changes are required when the number of battery cell packs changes, leading to increased costs and complexity
Solution Approach 1:
The housing is divided into a modular extruded portion that can be produced in standardized sections. These segments can be combined in different quantities and configurations to accommodate varying numbers of battery cell packs, eliminating the need for complete redesign when capacity changes are required.
Solution Approach 2:
The extruded housing portion is designed with universal features including standardized fastening elements, heat management surfaces, and mounting interfaces that can accommodate different numbers and types of energy storage units. This multi-functional design allows the same housing structure to serve various energy storage configurations.
2Adaptability or versatility
If sheet metal housings are used for energy storage, then the housing provides structural integrity, but tooling changes are required when configuration changes are needed, leading to increased costs
Solution Approach 1:
The housing configuration can be adjusted by changing parameters such as the length of the extruded portion, the number of fastening elements, and the arrangement of heat management surfaces, all of which can be modified through standard extrusion process adjustments rather than requiring new tooling designs.
Solution Approach 2:
The housing design incorporates dynamic adjustability through the extrusion process, allowing the same tooling to produce housing portions of varying lengths and configurations by adjusting extrusion parameters, stopping points, and process variables rather than requiring physical tooling changes.
3Ease of operation
If traditional housing designs with multiple apertures are used, then components can be accessed, but sealing becomes difficult and more parts are needed
Solution Approach 1:
The design extracts the sealing function from multiple distributed sealing elements and consolidates it into a single integrated sealing solution at the primary aperture, eliminating the need for multiple sealing parts while maintaining ease of component insertion through the extruded housing.
Data Source
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AI summary
A housing (1) for an energy storage is disclosed, wherein the housing (1) comprises an extruded portion (9) made by an extruding process, wherein the extruded portion (9) forms a cavity extending along an extruding direction (10). Further, an energy storage and a method for producing a housing are disclosed.