Segmented Battery Pack Housing for Electrolyte Leak Isolation
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Solution Overview
Problem
The existing battery pack manufacturing process is complex and costly due to the segmented encapsulation of cells, leading to increased manufacturing costs and fire risks from electrolyte leakage between cells.
Innovation Solution
A battery pack design featuring a housing with integrated slots for electrode assemblies, where each assembly is separated and sealed, reducing the need for segmented machining and preventing electrolyte flow between cells, using a circuit board for electrical connections and a cooling system to manage heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cells are respectively encapsulated and then integrally encapsulated, then each cell is protected, but the structure becomes complex and manufacturing cost increases
Solution Approach 1:
The battery pack is divided into multiple independent battery compartments, each housing a single cell. Each compartment is separately sealed with sealing rings, providing individual protection while maintaining overall structural simplicity. This segmentation allows each cell to be independently protected without requiring complex integrated encapsulation processes.
2Reliability
If cells are respectively encapsulated and then integrally encapsulated, then each cell is protected, but manufacturing cost increases
Solution Approach 1:
The battery pack adopts a modular segmented structure where each cell is housed in its own compartment with independent sealing. This allows for simplified manufacturing processes compared to complex integrated encapsulation, reducing production costs while maintaining reliable cell protection through individual sealing rings and partitions.
3Quantity of substance
If cells are placed close together for high capacity, then energy density increases, but electrolyte leakage between cells increases fire risk
Solution Approach 1:
The battery pack uses partition walls and sealing rings to divide the internal space into separate compartments for each cell. This segmentation prevents electrolyte from flowing between cells even when cells are positioned closely together, eliminating the fire risk associated with electrolyte leakage while maintaining high energy density through efficient space utilization.
Solution Approach 2:
Sealing rings and partition walls act as intermediary barriers between adjacent cells. These intermediaries prevent direct contact between electrolytes of different cells, blocking the potential pathway for electrolyte leakage and fire hazards while allowing the cells to be arranged in a compact configuration for high capacity.
4Reliability
If segmented encapsulation is used, then cell protection is improved, but manufacturing process becomes longer
Solution Approach 1:
The battery pack employs a pre-designed segmented structure with integrated compartments and sealing elements. This segmentation allows for streamlined assembly processes where cells can be individually placed into pre-formed compartments with built-in sealing, reducing the number of separate encapsulation steps required and shortening the overall manufacturing process time while maintaining cell protection.
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
Simplifies the manufacturing process, reduces costs, and minimizes fire risks by ensuring electrolyte containment and efficient heat management, while maintaining high capacity and power performance.
Implementation Method 1
A seal is arranged between the first cap and the opening. The seal is used for sealing a gap between the first cap and the opening, i.e., implementing sealing on one single accommodation space and preventing electrolyte from flowing out of the accommodation space.
Implementation Method 2
A cooling medium is accommodated in the second slot. The cooling medium is used for cooling the electrode assemblies so as to fulfill the aim of cooling.
Data Source
AI summary
A battery pack, including a housing, a circuit board, and a plurality of electrode assemblies. The housing includes a first surface and a second surface opposite to each other. The first surface is provided with a plurality of first slots. The battery pack further includes a plurality of first caps, and the plurality of first caps respectively cover the plurality of first slots to form a plurality of mutually separated accommodation spaces. The electrode assemblies each includes an electrode plate assembly, a first electrode tab, and a second electrode tab. The electrode plate assembly is accommodated in the accommodating space. The first tab and the second tab extend out of the accommodating space. At least one first electrode tab and at least one second electrode tab are electrically connected to the circuit board. The structure and the manufacturing process of the battery pack can be simplified.