Welded Battery Pack Enclosure for Fire Containment and Rigidity
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Solution Overview
Problem
Conventional battery pack enclosures are flimsy and expensive to produce, and they fail to effectively contain a fire, which is a critical issue as the demand for safe and efficient battery solutions grows with the advancement of electric vehicles.
Innovation Solution
A metal case enclosure design that includes a sealing rim and two components joined by welding, providing increased rigidity and fire containment capabilities, while being cost-efficient and easily manufactured, with features like breakaway mounts and a crush zone to manage impact and fire safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional enclosure materials and designs are used, then manufacturing cost is reduced and ease of manufacture is improved, but structural strength and fire containment capability deteriorate
Solution Approach 1:
The enclosure is divided into multiple separate components (first component with two or more sides, second component with at least one side) that are joined together through welding. This segmentation allows each component to be manufactured independently using standard fabrication processes, improving ease of manufacture while the welded assembly achieves the required structural strength and rigidity.
Solution Approach 2:
The enclosure uses a composite construction combining metal components joined by welding, creating a structure that achieves both high strength and fire containment capability. The welded metal construction provides the necessary structural integrity while remaining manufacturable through conventional metalworking processes.
2Reliability
If conventional enclosure designs are used, then manufacturing cost is reduced, but fire containment capability deteriorates
Solution Approach 1:
The enclosure is segmented into weldable components that can be assembled from standard metal stock, achieving fire containment through the welded metal construction rather than requiring specialized expensive materials. The welding process creates a sealed enclosure that contains fire while using readily manufacturable components.
Solution Approach 2:
The design changes the structural parameters by using thick-gauge metal components joined by welding, transforming the enclosure from a non-fire-resistant construction to a fire-containing structure. This parameter change (material thickness and joining method) achieves fire containment while remaining compatible with standard metal fabrication processes.
3Reliability
If rigid fire-containing enclosure is implemented, then fire containment capability and structural strength are improved, but manufacturing cost increases
Solution Approach 1:
The enclosure is divided into components that can be manufactured from standard metal inventory and joined through welding. This segmentation avoids the need for expensive custom-molded or specially fabricated single-piece enclosures, reducing manufacturing cost while achieving the required fire containment and structural strength through the welded assembly.
Solution Approach 2:
The design uses readily available, inexpensive metal stock (such as aluminum or steel sheets and plates) that can be cut and welded using standard shop equipment. These conventional materials and processes are far more cost-effective than specialized fire-resistant materials, achieving fire containment through proper welding and assembly rather than expensive material selection.
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 results in a cost-effective, safe, and rigid battery pack enclosure that can efficiently contain fires, enhancing the realization of electric vehicle technology by ensuring safety and manufacturing efficiency.
Implementation Method 1
the sealing rim, the first component, and the second component are all joined together by welding
Data Source
AI summary
Aspects relate to systems and methods for manufacture of a battery pack including a metal case circumscribing an inner volume circumscribed on all but one open side, where the case additionally includes a sealing rim positioned at least partially about the open side, a first component that includes at least two or more sides of the case, and a second component that includes at least one other side of the case, at least a battery module installed within the inner volume of the case, and an inner panel installed within the inner volume, between the case and the at least a battery module. In some aspects, sealing rim, first component, and second component are all joined together by welding.