Mechanical Design of Battery Packs - II — Lesson 2

This lesson covers the process of determining the design parameters for a battery pack, including pack capacity, voltage, current, and weight. It delves into the forces that can act on a battery pack, such as compression, tension, shear, torsion, and bending. The lesson also explains the concepts of stress, strain, and deformation. It further discusses the forces acting on a battery pack and how to determine the dimensions and thickness of the base plate that can withstand the required load. The lesson also introduces the methodology for material selection and explains how to calculate the maximum deflection and stress in the base plate. The lesson concludes with a discussion on battery swelling and its impact on cell life.

Video Highlights

00:19 - Introduction
02:52 - Methodology to determine the best material for a specific application, using the example of a base plate for a battery pack
03:10 - Process of translating, screening, ranking, and supporting information to select the best material
16:02 - Base plate calculations (contd.)
24:37 - Phenomenon of battery swelling, which mostly occurs in pouch cells and prismatic cells
27:10 - How uneven expansion and contraction due to temperature gradients can induce thermal stress in prismatic cells

Key Takeaways

- The design parameters of a battery pack include pack capacity, voltage, current, and weight.
- Various forces can act on a battery pack, including compression, tension, shear, torsion, and bending.
- The Ashby methodology is a useful tool for selecting the best material for a specific application.
- The maximum deflection and stress in the base plate can be calculated using specific formulas.
- Battery swelling can impact cell life, and it is crucial to provide sufficient constraints to prevent this phenomenon.