Stackable Battery Cartridge Module with Foam Thermal Interface
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Solution Overview
Problem
The assembly of battery modules for electric vehicles is challenging due to the difficulty in aligning cooling fins with battery cells, which increases costs and affects the feasibility of electric vehicles.
Innovation Solution
A battery module assembly comprising stacked battery cartridges with a foam layer between cells to allow expansion and maintain contact with cooling fins, and a receiving assembly that holds these cartridges between heat sink sections for improved alignment and thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional battery module assembly methods are used with separate cooling fins and battery cells, then manufacturing flexibility is maintained, but alignment difficulty increases and assembly complexity worsens
Solution Approach 1:
The patent combines the cooling fin and battery cell into a single integrated cartridge assembly. The cooling fin is directly attached to the battery cell, forming a unified structure that eliminates the need for separate alignment operations. This merging of previously separate components resolves the alignment difficulty and simplifies the manufacturing process.
2Temperature
If rigid bonding between battery cells and cooling fins is used, then thermal conduction is improved, but cell expansion during cycling is restricted
Solution Approach 1:
The patent changes the mechanical property parameter of the bonding material from rigid to compliant. The bonding material is specifically designed to be compliant enough to accommodate battery cell expansion during cycling while still providing sufficient thermal conduction. This parameter change allows the system to simultaneously achieve good thermal management and cell stability.
3Adaptability or versatility
If multiple separate components are used for battery modules, then component functionality is optimized, but assembly precision requirements increase
Solution Approach 1:
The patent segments the battery module into multiple standardized cartridges, where each cartridge is a self-contained unit with pre-integrated cooling fins and battery cells. This segmentation allows each cartridge to be manufactured and tested independently with optimized functionality, while the standardized interface reduces assembly precision requirements when combining multiple cartridges into a complete battery module.
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
The solution simplifies the assembly process, enhances thermal management, and reduces costs by ensuring intimate contact between battery cells and cooling elements, thereby improving the efficiency and feasibility of battery modules for electric vehicles.
Implementation Method 1
a foam layer interposed between the first battery cell and the second battery cell which allows for cell expansion during cycling
Implementation Method 2
The plurality of battery cartridges are positioned between a first heat sink section and a second heat sink section. Each battery cartridge is bonded to the first heat sink section and second heat sink section.
Data Source
AI summary
A battery assembly includes a plurality of stacked battery cartridges. Each battery cartridge includes a first receptacle unit, a battery cell stack, and a second receptacle unit positioned within first receptacle unit. The battery cell stack includes a first battery cell, a second battery cell, and a foam layer interposed between the first battery cell and the second battery cell. The battery cell stack is positioned within the first receptacle unit, with the second receptacle unit compressing the battery cell stack. The battery module assembly also includes a receiving assembly that holds the plurality of battery cartridges.