Integral Circuitry Pouch Frame for Battery Module Packaging
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Solution Overview
Problem
There is a need for improved battery systems in xEVs that can increase travel distance without recharging, enhance performance, and reduce costs, while also addressing packaging challenges in converting traditional vehicles to hybrid electric vehicles.
Innovation Solution
The use of lithium ion battery modules with a form factor equivalent to traditional lead acid batteries, incorporating frames with internal circuitry for electrical connections, sensors for monitoring, and a cell interconnect board to collect data and send it to a control system, along with advanced heat management systems like phase change materials and active cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium ion battery modules are used to increase travel distance and improve performance, then energy storage capacity and power output are improved, but device complexity and packaging challenges worsen
Solution Approach 1:
The frame structure is merged with circuit board functionality, integrating electrical connections, sensors, and control electronics directly into the structural frame that holds the battery cells. This eliminates separate mounting brackets and wiring harnesses, reducing packaging complexity while maintaining high energy storage capacity
Solution Approach 2:
The frame serves multiple functions simultaneously: it provides structural support for the battery cells, acts as a circuit board for electrical connections, houses sensors for monitoring, and integrates cooling channels. This multi-functionality reduces the number of separate components needed, simplifying packaging while enabling advanced features
2Productivity
If advanced thermal management systems are implemented to enhance performance, then operational efficiency is improved, but device complexity increases
Solution Approach 1:
The cooling channels are integrated directly into the frame structure that also serves as the circuit board and structural support. This merging of thermal management functionality into the existing frame eliminates the need for separate cooling plates or heat sinks, reducing system complexity while improving operational efficiency through effective heat dissipation
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 solution enables longer travel distances, improved performance, and reduced costs by providing multiple voltage levels from a single package, simplifying the conversion of traditional vehicles to xEVs and enhancing thermal management for efficient operation.
Implementation Method 1
advanced heat management systems like phase change materials and active cooling
Data Source
AI summary
A battery cell assembly for use in a battery module including a battery cell that includes a positive electrode and a negative electrode and a rigid frame coupled to the battery cell. The rigid frame includes a first frame connector and a second frame connector. The frame is configured to facilitate electrical coupling of the positive electrode of the battery cell with the first frame connector, and to facilitate electrical coupling of the negative electrode of the battery cell with the second frame connector. The first and second frame connectors are configured to interface with frame connectors of other battery cell assemblies to facilitate physical and electrical connection of a plurality of battery cell assemblies disposed in a stacked orientation relative to each other.