Removable-Side Battery Cell Housing for Serviceable Thermal Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery cells, particularly prismatic cells, face challenges with mechanical robustness, thermal management, and ease of maintenance due to mechanical stress, overheating, and complex electrical coupling, which can lead to internal damage and inefficiencies.
Innovation Solution
Incorporating a center post for mechanical support, a thermally conductive potting material for stabilization and thermal management, a removable side for ease of maintenance, and a cooling configuration with coolant lines for thermal control, along with stacked electrical conductors for efficient electrical coupling and venting structures for gas management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sidewalls of housing are reinforced to protect against mechanical stress, then mechanical robustness is improved, but volume, materials, mass, or ease of integration increases undesirably
Solution Approach 1:
The center post is nested within the housing internal volume, utilizing the central space without extending to the sidewalls. This internal structural element provides mechanical reinforcement from within, avoiding the need to increase housing thickness or external dimensions while still protecting against mechanical stress
Solution Approach 2:
Instead of reinforcing the sidewalls (surface dimension), the solution introduces a three-dimensional center post structure that spans the internal volume. This shifts the reinforcement approach from two-dimensional wall thickening to three-dimensional internal structural support, maintaining compact external dimensions
2Strength
If housing is made sealed and robust, then mechanical protection is improved, but ease of maintenance deteriorates
Solution Approach 1:
The housing is segmented into removable panels that can be detached to provide access to internal components. This segmentation allows the housing to maintain its sealed and robust structure while enabling maintenance activities by allowing controlled access to the interior without compromising overall structural integrity
Solution Approach 2:
The housing transitions from a completely fixed structure to one with dynamic, removable panels. This allows the housing to adapt between a sealed protected state during operation and an accessible state during maintenance, combining both mechanical robustness and ease of maintenance requirements
3Use of energy by moving object
If complex electrical coupling is used to achieve efficient power distribution, then electrical efficiency is improved, but device complexity increases
Solution Approach 1:
Multiple electrical conductors are merged and stacked in a compact arrangement, combining multiple electrical pathways into a unified structure. This reduces the overall complexity of the electrical coupling system while maintaining efficient power distribution across multiple energy units through the stacked conductor configuration
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
Enhances mechanical robustness, improves thermal management, facilitates easy maintenance, and optimizes electrical coupling and venting, resulting in a more reliable and efficient battery cell design.
Implementation Method 1
a thermally conductive potting material is provided for mechanical and thermal support of the battery cells
Implementation Method 2
a cooling configuration with coolant lines for thermal control
Data Source
AI summary
In accordance with some embodiments of the present disclosure, a battery cell includes a housing including an opening, a removable side configured to, in an installed position, cover the opening, and at least one energy unit coupled to the removable side such that removal of the removable side causes the at least one energy unit to be removed from the housing. In some embodiments, in the installed position, the removable side is coupled to the housing and forms a front panel of the housing. In some embodiments, in the installed position, the removable side covers the opening to form a sealed enclosure around the at least one energy unit. In some embodiments, the removable side is coupled to a frame member that is configured to, in the installed position, be arranged adjacent to an inner surface of the housing.