Weld-Free Battery Module Casing for Easy EV Recycling
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Solution Overview
Problem
Battery clamshells used in electric vehicles are difficult to disassemble for recycling due to their welded construction, making the recycling process inefficient.
Innovation Solution
A battery assembly design featuring a casing with battery modules that are not welded, using electrically-insulative polymeric materials with graphene for enhanced thermal conductivity, and a locking mechanism that allows for easy assembly and disassembly without welding, enabling the replacement of cells during recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded construction is used to assemble battery modules, then structural strength and reliability are improved, but disassembly difficulty and recycling complexity increase
Solution Approach 1:
The battery module is divided into separable components: a receiver, posts, and a locking member. The locking member can be disengaged from the posts to separate the battery cell assembly from the receiver, enabling easy disassembly and recycling while maintaining structural integrity during use.
Solution Approach 2:
The locking mechanism utilizes phase change or state transformation through the lateral sliding motion of the locking member along the posts. The locking member transitions between engaged and disengaged states, providing secure attachment during operation while allowing easy separation for recycling.
2Reliability
If polymeric material is used for receiver and locking member, then electrical insulation is improved, but thermal conductivity decreases
Solution Approach 1:
The receiver and locking member are made from composite polymeric materials that combine electrical insulation properties with enhanced thermal conductivity. This composite material structure allows the components to provide both electrical isolation to prevent short circuits and adequate thermal management for battery operation.
3Temperature
If graphene is added to polymeric material, then thermal conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
Graphene is incorporated into the polymeric material to create a composite with enhanced thermal conductivity. The graphene-polymer composite maintains the electrical insulation benefits of the polymer while adding superior thermal management capabilities, and can be manufactured using existing composite material processing techniques.
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
Facilitates easier disassembly and recycling of battery assemblies, reduces assembly complexity, and enhances thermal management while avoiding short circuits, allowing for quicker and safer assembly and maintenance with reduced weight and size.
Implementation Method 1
include graphene to enhance thermal conductivity for heat sinking
Implementation Method 2
the locking member is slid laterally to the posts along the receiver to engage with the posts
Data Source
AI summary
The present invention relates to a battery assembly including a casing, and battery modules received in the casing. The casing and the battery modules may be easily disassembled as they are not welded, and cells within the battery modules replaced during recycling. Similarly, during assembly, there is preferably no welding or deforming of parts.