Pouch Cell Battery Pack Assembly With Adhesive Bonding and FPC Positioning
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Solution Overview
Problem
Pouch battery cells face challenges in integration into CTP battery packs due to poor resistance to external impacts and difficult assembly, leading to suboptimal space utilization and diminished energy density.
Innovation Solution
A battery pack design utilizing a casing with a lower housing, thermal conductive structural adhesive, foaming adhesive, and flexible printed circuit board assembly, which includes a flexible printed circuit board secured by plastic sheets and hot pressing films, eliminating the need for plastic brackets and ensuring precise positioning of temperature sampling terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pouch battery cells are directly integrated into CTP battery packs, then assembly simplicity is improved, but space utilization deteriorates due to poor resistance to external impacts and difficult assembly
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a subset of pouch battery cells. This segmentation allows for optimized arrangement of cells within modules while maintaining the overall CTP architecture, thereby improving space utilization without compromising assembly simplicity.
Solution Approach 2:
Battery modules are nested within the battery pack structure, with each module containing nested battery cells. This nested arrangement maximizes space utilization by efficiently packing cells within modules and modules within the pack, while the modular design maintains assembly simplicity.
2Quantity of substance
If multiple battery modules are connected in series and parallel to form battery pack, then energy density is improved, but device complexity worsens due to structural components and electrical connection components
Solution Approach 1:
Multiple battery modules are merged into a unified CTP battery pack structure, sharing common structural components and electrical connection systems. This merging reduces the total number of discrete structural components while maintaining high energy density through the series and parallel connection of multiple cells within the integrated pack.
Solution Approach 2:
The battery pack structure is designed with universal components that serve multiple functions: structural support, thermal management, and electrical connection. This multi-functionality reduces the number of dedicated structural components needed, thereby reducing device complexity while maintaining high energy density.
3Ease of operation
If pouch battery cells are used in CTP battery packs, then ease of assembly is improved, but reliability deteriorates due to poor resistance to external impacts
Solution Approach 1:
Protective structures and cushioning materials are pre-installed within the battery module and pack designs to absorb and distribute external impacts before they reach the pouch battery cells. This beforehand cushioning protects the cells from damage while maintaining ease of assembly through the integrated protective design.
Solution Approach 2:
The battery module and pack structures utilize composite materials that combine the flexibility and ease of assembly of pouch cells with the impact resistance of stronger structural materials. This composite approach maintains ease of assembly while significantly improving resistance to external impacts.
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
Improves spatial utilization, enhances energy density, simplifies assembly, and reduces costs by securing the flexible printed circuit board and temperature sampling terminals, while maintaining precise positioning and sampling accuracy.
Implementation Method 1
A thermal conductive structural adhesive, wherein the battery cell stack and the bottom plate of the lower housing are directly bonded and fixed through the thermal conductive structural adhesive
Implementation Method 2
A foaming adhesive, wherein the foaming adhesive is filled and connected between the tab side of the battery cell stack and the lower housing
Data Source
AI summary
Provided is a battery pack, including: a casing, the casing includes a lower housing; a battery cell stack, the battery cell stack includes multiple pouch battery cells, and the battery cell stack is configured in the lower housing; a thermal conductive structural adhesive, the battery cell stack and the bottom plate of the lower housing are directly bonded and fixed through the thermal conductive structural adhesive; a foaming adhesive, the foaming adhesive is filled and connected between the tab side of the battery cell stack and the lower housing; a flexible printed circuit board assembly, the flexible printed circuit board assembly includes: a flexible printed circuit board and an insulating connecting sheet, the flexible printed circuit board is fixedly connected to the battery cell stack through the insulating connecting sheet.