Designing of aluminium case lid of prismatic battery cell for laser powder bed fusion

The present work provides an overview on an additive manufacturing (AM) design case of a novel battery cell lid structure (patent pending) for electrical vehicle applications. The benefits of AM have not yet been explored on metal case structures of prismatic battery cells. The method allows the manufacturing of complex hollow structures and integration of multiple functions in one part. The main challenge is to address thermal management in an optimal location in the battery cell. More efficient charging and discharging by maintaining the batteries at optimum operating conditions allows a longer battery lifetime. Recent research shows that elevating the charging temperature enables significantly shorter charging times. The aim of this study is to develop a lid structure to support higher peak current, faster charging, and reduced production steps and enable mass customization. The optimum performance simulated with computational fluid dynamics calculations is realized to determine the optimum design. The design case study is verified via laser powder bed fusion prototypes. This study shows that it is possible to produce integrated thermal management liquid channels to the battery lid. Significant improvement is achieved with localized battery cell temperature management. The novel design integrates six critical functionalities of the lid in one part. The design of the features is optimized to avoid support structures in AM and to maximize the number of parts in the printing chamber volume. The better thermal management extends the driving range of the vehicle and improves vehicle safety. Reducing the parts significantly simplifies cell production.