Vehicle Starter Battery Cell Compression Housing
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Solution Overview
Problem
Existing vehicle starter batteries face challenges in securely housing and connecting prismatic cells to prevent delamination and swelling, while ensuring efficient electrical connections and current distribution.
Innovation Solution
A starter battery design featuring a housing with a tray and lid that applies compressive force to prevent cell delamination, using a dielectric frame with weld members and a flex circuit to support bus bars and terminals, and a thermistor for voltage sensing and cell balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a housing with tray and lid is used to contain the cell array, then the battery provides structural support and containment, but the housing may not sufficiently prevent cell delamination and swelling without additional securing mechanisms
Solution Approach 1:
The tray is designed with recesses that receive the cell array before final assembly, pre-positioning the cells in a secured manner that prevents delamination and swelling during subsequent assembly steps
Solution Approach 2:
A compression plate is introduced as an intermediary component between the lid and cell array, applying uniform compressive force to secure the cells and prevent delamination without requiring complex direct attachment mechanisms
2Volume of moving object
If prismatic cells are stacked to form an array, then the battery achieves compact configuration, but the cells are susceptible to delamination and swelling during operation
Solution Approach 1:
The pouch-type prismatic cells are enclosed in flexible pouch structures that maintain compact stacking while the external compression plate applies force to prevent swelling and delamination during operation
Solution Approach 2:
The tray recesses are designed to pre-position and secure the stacked cells in a stable configuration before assembly is completed, preventing delamination from the outset
3Reliability
If tabs are folded over weld members and bonded, then reliable electrical connections are achieved, but the connection process becomes complex
Solution Approach 1:
The tabs are designed to be folded over the weld members in a self-aligning manner, where the folding action itself positions the tabs correctly for bonding, reducing the need for complex alignment fixtures or procedures
Solution Approach 2:
The mechanical folding of tabs replaces more complex mechanical attachment systems, using simple bending and bonding operations to achieve reliable electrical connections
4Reliability
If bus bars are used for current distribution, then efficient electrical connectivity is achieved, but the bus bar structure and welding components increase device complexity
Solution Approach 1:
The bus bar structure is integrated with the tray and lid components, merging the electrical current distribution function with the mechanical housing structure, thereby reducing overall device complexity while maintaining efficient connectivity
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 design effectively secures and connects prismatic cells, preventing delamination and swelling, while ensuring reliable electrical connections and efficient current distribution, enhancing the battery's performance and longevity.
Implementation Method 1
the housing includes a tray and a lid attached with the tray such that the housing provides a compressive force sufficient to prevent cell delamination and to constrain expansion or swelling of the cells during operation
Implementation Method 2
An electric battery may use an electrochemical cell to convert chemical energy to electric energy. The basis of this process is to derive electric energy in the form of the liberation of electrons as a result of a chemical reaction
Implementation Method 3
A battery cell comprises an anode and cathode with an electrolyte used to carry ions between the anode and cathode
Implementation Method 4
A starter battery design featuring a housing with a tray and lid that applies compressive force to prevent cell delamination, using a dielectric frame with weld members and a flex circuit to support bus bars and terminals
Data Source
AI summary
A starter battery is provided comprising a plurality of pouch-type prismatic cells stacked to form an array and configured to output a voltage sufficient to start a vehicle engine. The starter battery further includes a housing configured to contain the array wherein the housing includes a tray and a lid attached with the tray such that the housing provides a compressive force sufficient to prevent cell delamination and to constrain expansion or swelling of the cells during operation.