Through-Cell Battery Pack Fasteners for Compression and Thermal Access
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Solution Overview
Problem
Conventional battery designs face challenges in monitoring and thermal management due to extended dimensions, leading to reduced energy density and increased packaging complexity, as sensors and probes often extend into cell regions, causing volumetric and gravimetric energy density losses and complicating cell swelling compensation.
Innovation Solution
The integration of fasteners that extend through the active regions of battery cells allows for reduced external structural component thickness, improved energy density, enhanced monitoring capabilities, and efficient thermal management by providing access to all cells within the stack and facilitating uniform pressure distribution and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors and probes are extended into cell regions for monitoring and thermal management, then monitoring capability is improved, but volumetric energy density is reduced
Solution Approach 1:
The fastener structure performs multiple functions simultaneously: it provides mechanical compression to maintain cell contact, enables thermal management through integrated channels, and facilitates monitoring through accessible mounting points. This eliminates the need for separate sensors and probes extending into cell regions, thereby maintaining volumetric energy density while achieving comprehensive monitoring and thermal management capabilities.
Solution Approach 2:
The patent combines previously separate functions (compression, thermal management, and monitoring access) into a single integrated fastener structure. The fastener integrates compression plates, thermal channels, and sensor mounting features, consolidating multiple components into one element that serves all three purposes without requiring additional space-invasive extensions into the battery cells.
2Strength
If external structural component thickness is increased to accommodate monitoring and thermal management, then structural integrity is improved, but energy density is reduced
Solution Approach 1:
The fastener structure nests multiple functional elements within a compact form factor. The compression plates, thermal channels, and sensor mounting features are nested within the fastener body itself, allowing these functions to be achieved without increasing the overall external dimensions or reducing the active battery volume, thereby maintaining both structural integrity and energy density.
3Ease of manufacture
If conventional battery configurations are used, then manufacturing simplicity is maintained, but packaging efficiency and monitoring capability are reduced
Solution Approach 1:
The battery pack is segmented into modular units with standardized fastener components that can be independently manufactured and assembled. The fastener design allows for modular assembly where compression plates, thermal channels, and sensor mounts are integrated into discrete fastener units that can be manufactured separately and then assembled to the battery cells, simplifying the overall manufacturing process while improving packaging efficiency.
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
This solution increases battery energy density, improves pack footprint, and enables effective monitoring and thermal management, while maintaining structural integrity and accommodating cell swelling pressures, thereby overcoming the limitations of conventional designs.
Implementation Method 1
a retaining member compressibly coupling the compression plate with the base plate
Implementation Method 2
facilitating uniform pressure distribution
Implementation Method 3
The base plate may define a plurality of channels configured to receive a heat exchange fluid
Implementation Method 4
efficient thermal management by providing access to all cells within the stack and facilitating uniform pressure distribution and heat transfer
Data Source
AI summary
Energy storage devices, battery cells, and batteries of the present technology may include a base plate. The batteries may include a first circuit board overlying the base plate. The batteries may include a battery stack overlying the first circuit board and electrically coupled with the first circuit board. The battery stack may include a plurality of battery cells. The battery stack may define an aperture through an active region of the battery stack. The batteries may include a second circuit board overlying the battery stack and electrically coupled with the battery stack. The batteries may include a compression plate overlying the second circuit board. The batteries may include a retaining member compressibly coupling the compression plate with the base plate. The retaining member may extend through the aperture through the active region of the battery stack.