Spacer Blocks Adhesive Path for Battery Vent Safety
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Solution Overview
Problem
Conventional vehicle systems, particularly electric and hybrid-electric vehicles, are limited by traditional frame sizes, shapes, and materials, failing to leverage new technologies and infrastructure, and lack adaptability to changing demands and safety advancements.
Innovation Solution
A modular vehicle frame with interchangeable subsystems and power source modules, including quick-release mechanisms and redundant power distribution systems, allowing for easy component swapping and integration of advanced technologies, along with electromagnetic coupling features for vehicle connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermally conductive structural adhesive is used to bond the cooling plate to the battery cell, then thermal conductivity and structural strength are improved, but the adhesive may block the pressure relief vent path creating safety hazards
Solution Approach 1:
The bonding interface is segmented into two distinct zones: a first bonding zone with thermally conductive adhesive for thermal management, and a second bonding zone with vent access maintained clear of adhesive for safety. This spatial segmentation resolves the contradiction by allowing both strong bonding and unobstructed venting.
Solution Approach 2:
Different regions of the bonding interface are assigned different properties: the first region receives thermally conductive adhesive optimized for heat transfer, while the second region maintains vent access with no adhesive or reduced adhesive to preserve pressure relief functionality. This local differentiation allows simultaneous optimization of thermal performance and safety.
2Strength
If a rigid frame structure is used for vehicle construction, then structural strength and stability are improved, but adaptability to new technologies and infrastructure is reduced
Solution Approach 1:
The vehicle frame is divided into a rigid primary structure for strength and stability, and modular subsystems that can be independently replaced or upgraded. This segmentation allows the overall structural integrity to be maintained while enabling adaptability through component-level modifications.
Solution Approach 2:
The frame system transitions from a completely static rigid structure to a dynamic hybrid system where the primary structure remains fixed for strength, but subsystems can be dynamically replaced or reconfigured. This enables the vehicle to adapt to new technologies while maintaining structural stability.
3Ease of manufacture
If traditional vehicle subsystems are used with alternative power sources, then implementation simplicity is improved, but failure to leverage new technology benefits occurs
Solution Approach 1:
The vehicle platform is designed with universal interfaces and modular subsystems that can accommodate multiple power source types (battery electric, hybrid, fuel cell) and future technologies. This multi-functionality allows the same base platform to leverage benefits of different technologies without requiring complete redesign.
Solution Approach 2:
The vehicle system evolves from static traditional subsystems to dynamic modular components that can be selectively upgraded. This enables progressive adoption of new technologies while maintaining ease of manufacture through standardized interfaces and assembly processes.
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 adaptability, reduces weight and power consumption, improves safety, and enables efficient energy sharing and recovery, while ensuring secure and efficient replacement of components.
Implementation Method 1
a thermally conductive potting material disposed between the one or more power cells and the cooling plate
Implementation Method 2
each power cell comprising a pressure vent on a side of the power cell, the pressure vent adapted to relieve an internal pressure of the cell when the internal pressure exceeds a threshold
Data Source
AI summary
Embodiment include a power source module comprising one or more power cells. Each power cell can comprise a pressure vent on a side of the power cell. The pressure vent can be adapted to relieve an internal pressure of the cell when the internal pressure exceeds a threshold. A cooling plate can be disposed adjacent and substantially parallel to a side of the one or more power cells having the pressure vent. One or more spacers can be disposed between each of the one or more power cells and the cooling plate and substantially surrounding the pressure vent of one of the one or more power cells. A thermally conductive potting material can be disposed between the one or more power cells and the cooling plate. Each spacer prevents the potting material from intruding into an area around the vent of one of the one or more power cells.