Hybrid Battery Module Housing for Cell Expansion and Sealing
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Solution Overview
Problem
Existing battery module housings face challenges in accommodating cell dimension changes during operation, leading to potential cell damage, and have limitations in height due to the deep drawing process of metal foil laminate pouch cells, which affects packing efficiency and sealing complexity.
Innovation Solution
A battery module housing that combines a rigid frame with flexible metal foil laminate cover elements, allowing for cell growth accommodation and improved sealing, while avoiding the limitations of deep drawing and flange-associated issues, by using a tubular frame and heat-sealed cover elements to form a sealed module housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid prismatic housing is used, then structural integrity is improved, but cell damage occurs due to inability to accommodate cell dimension changes
Solution Approach 1:
The housing is divided into a rigid frame structure and separate flexible cover elements. The frame provides structural integrity while the flexible covers accommodate cell dimension changes, resolving the contradiction between rigidity and adaptability.
Solution Approach 2:
Flexible cover elements made of metal foil laminate material are used to enclose the cell stack. These flexible covers can deform to accommodate cell expansion during operation while maintaining protection, solving the contradiction between structural strength and cell dimension accommodation.
2Ease of manufacture
If deep drawing process is used for metal foil laminate pouch cells, then manufacturing is achieved, but height limitations and sealing complexity increase
Solution Approach 1:
The housing is segmented into a frame and separate cover elements that are attached afterward. This eliminates the need for complex deep drawing and flange sealing, simplifying the manufacturing process while maintaining structural integrity.
Solution Approach 2:
The complex deep drawing process and flange structures are extracted from the design. Instead, simple cover elements are attached to the frame using straightforward methods, reducing sealing complexity while achieving the same enclosure function.
3Adaptability or versatility
If rigid frame with flexible covers is used, then cell growth accommodation is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is divided into a rigid frame and flexible cover elements that can be manufactured separately using simple processes, then assembled. This maintains manufacturing simplicity while achieving cell growth accommodation through the flexible covers.
Solution Approach 2:
Flexible metal foil laminate cover elements are used to provide cell growth accommodation. These covers can be manufactured using simple processes and attached to the rigid frame, achieving adaptability without significantly increasing manufacturing complexity.
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 solution enhances cell protection, improves packing efficiency, and simplifies sealing and mounting of ancillary structures, reducing the risk of cell damage and increasing the structural integrity of the battery module.
Implementation Method 1
a peripheral edge of the first cover element is joined to the frame along the entirety of the peripheral edge of the first cover element
Data Source
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Figure 3
Figure 4~5
AI summary
A battery module incorporates features of both prismatic housings and metal foil laminate pouch housings, and is configured to receive and support electrochemical cells. The battery module housing includes a rigid tubular frame and flexible cover elements that are joined to the frame and close the open ends of the frame. The frame has an inner surface that faces the cells, an outer surface that is opposed to the inner surface, a first edge that joins the inner surface to the outer surface at one open end of the frame, and a second edge that joins the inner surface to the outer surface at the opposed open end of the frame. The first cover element overlies and closes the one open end of the frame and the second cover element overlies and closes the other open end of the frame.