Pouch Cell Battery Pack Layout Using Adhesive Bonding and Flat Cables
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Solution Overview
Problem
Pouch cells face integration challenges in CTP type battery packs due to difficulty in withstanding external impacts and poor assembly properties, leading to low space utilization and energy density.
Innovation Solution
A battery pack design that includes a casing with a battery cell stack of pouch cells bonded by a thermally conductive structural adhesive, using a foaming adhesive for fixation, and a flexible circuit board assembly with flexible flat cables for signal transmission, eliminating the need for low-voltage wiring harnesses, and utilizing a connecting assembly with adapters to secure the cables, thereby improving space utilization and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pouch battery cells are directly integrated into the CTP type battery pack, then the assembly process is simplified, but the space utilization and energy density remain low due to poor assembly properties
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a subset of battery cells. This segmentation allows for optimized arrangement of cells within each module, improving space utilization while keeping the assembly process manageable through modular construction
Solution Approach 2:
The patent employs three-dimensional stacking arrangement of battery cells within modules, utilizing vertical space more effectively. This dimensional optimization increases the quantity of cells that can be packed into the available volume without complicating the assembly process
2Ease of manufacture
If pouch battery cells are directly integrated into the CTP type battery pack, then the assembly process is simplified, but the space utilization and energy density remain low
Solution Approach 1:
By segmenting the battery pack into modules with optimized cell arrangements, the design achieves higher energy density through better space utilization while maintaining ease of assembly through standardized module construction
Solution Approach 2:
The patent uses composite structural designs combining different materials and configurations within the battery module to maximize energy density while preserving assembly simplicity
3Reliability
If traditional wiring harnesses are used for connecting battery management system, then the connection is stable, but the size and weight of the battery pack increase
Solution Approach 1:
The patent replaces traditional mechanical wiring harnesses with flexible flat cables for connecting the battery management system. This substitution maintains electrical connection reliability while significantly reducing the weight and volume of the connecting components
Solution Approach 2:
Flexible flat cables are used instead of rigid wiring harnesses, providing both mechanical flexibility and weight reduction. These thin-film cables maintain stable electrical connections while minimizing the overall battery pack weight
4Reliability
If traditional wiring harnesses are used for connecting battery management system, then the connection is stable, but the size of the battery pack increases
Solution Approach 1:
Replacing wiring harnesses with flexible flat cables reduces the volume occupied by connection components, allowing for more compact battery pack design while maintaining connection stability
Solution Approach 2:
The use of thin-film flexible cables minimizes the space required for electrical connections, reducing overall battery pack size while preserving reliable electrical connectivity
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 design enhances space utilization and energy density while making installation more convenient by using a direct bonding method and flexible flat cables, reducing the size and weight of the battery pack.
Implementation Method 1
a thermally conductive structural adhesive, and the battery cell stack and the base plate of the lower case are directly bonded and fixed by the thermally conductive structural adhesive
Implementation Method 2
A foaming adhesive is provided, and the foaming adhesive is filled and connected between the electrode tab side of the battery cell stack and the lower case
Data Source
AI summary
Disclosed is a battery pack including: a casing including a lower case; a battery cell stack including multiple pouch battery cells, including two opposite electrode tab sides and side surfaces adjacent to electrode tab sides, and disposed in the lower case; a thermally conductive structural adhesive directly bonding and fixing the battery cell stack and a base plate of the lower case; a foaming adhesive filling and connecting between the electrode tab side and the lower case; a battery management system; a flexible circuit board assembly including a flexible printed circuit board; a side plate fixed to the side surface; a connecting assembly including a flexible flat cable and an adapter, in which the flexible flat cable is disposed on the side surface and connected and fixed to the side plate through the adapter, and the battery management system and the flexible printed circuit board are communicatively connected through the connecting assembly.