Shared Partition Battery Casing for Thermal Homogeneity

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Solution Overview

Problem

High voltage battery systems for electric vehicles face issues with thermal and pressure heterogeneity, misalignment, and non-uniform compressive forces, leading to electrical connection problems and inefficiencies in existing battery arrays composed of individual prismatic Li-ion cells.

Innovation Solution

A cell casing with shared partitions replaces individual cell walls, providing weight, size, and cost savings, improved alignment, thermal homogeneity, and reduced need for inter-cell cooling mechanisms, enhancing mechanical rigidity and ease of build process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If individual cell walls are used to separate each prismatic Li-ion cell, then each cell is independently protected, but the battery system becomes heavier and larger

Engineering Contradiction:

Improvecell protectionVSAvoidbattery system weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Adjacent cell walls are merged into shared partitions that serve multiple cells simultaneously. The partition walls are common to two adjacent cells, eliminating redundant structural elements and reducing overall material usage while maintaining individual cell protection and independence.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If individual cell walls are used to separate each prismatic Li-ion cell, then each cell is independently protected, but the battery system volume increases

Engineering Contradiction:

Improvecell protectionVSAvoidbattery system volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If cells are arranged in a face-to-face configuration, then the battery system can be assembled, but thermal and pressure heterogeneity occurs

Engineering Contradiction:

Improveassembly capabilityVSAvoidthermal uniformity

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

Different regions of the battery system are provided with different local characteristics. Thermal management channels are strategically positioned in specific locations to address local heat generation patterns, ensuring uniform temperature distribution across the entire battery pack while maintaining the face-to-face cell configuration.

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If cells are arranged in a face-to-face configuration, then the battery system can be assembled, but misalignment and non-uniform compressive forces occur

Engineering Contradiction:

Improveassembly capabilityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Alignment features and positioning structures are pre-integrated into the casing and cell holder assembly during manufacturing. These preliminary alignment mechanisms guide the cells into correct positions during assembly, preventing misalignment and ensuring uniform distribution of compressive forces before the battery system is fully assembled.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10686166B2Multiple cell integrated casings

Publication Date: 2020.06.16 FORD GLOBAL TECH LLC

AI summary

The disclosure provides a battery cell casing for holding a plurality of cell elements, each electrode structure in its own compartment. The disclosed casing eliminates the need for some individual cell walls and replaces them with shared wall partitions.