Battery Cell Geometry for Filling Module Mounting Dead Space
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Solution Overview
Problem
Conventional battery modules have empty spaces due to protruding mounting parts, which increase the size unnecessarily and do not contribute to battery capacity, making it challenging to maximize battery cell capacity within a limited module case size.
Innovation Solution
A battery cell design with a main cell part and an auxiliary cell part that fills the internal space and empty spaces between mounting parts, featuring a concave-convex shape and folding sealing portions to optimize space usage within the module case, allowing for a pouch-type or can-type secondary battery configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional rectangular battery cell is used in a module case with protruding mounting parts, then the mounting parts can be securely attached, but empty spaces are formed between the mounting parts that increase the module size without contributing to battery capacity
Solution Approach 1:
The battery cell transitions from a conventional rectangular shape to a three-dimensional shape with protrusions that extend into the empty spaces between mounting parts. This dimensional change allows the cell to utilize previously wasted space, reducing the overall module case volume while maintaining secure mounting part attachment.
Solution Approach 2:
The battery cell's protrusions are nested within the empty spaces formed by the mounting parts arrangement. This nesting approach allows the cell to occupy the interstitial regions between mounting parts, effectively packing more capacity into the same module case volume without interfering with mounting part attachment.
2Volume of stationary object
If the module case size is reduced to meet vehicle design requirements, then the battery pack can be compacted, but the battery cell capacity is insufficient to provide adequate range
Solution Approach 1:
The battery cell's geometric parameters are changed from a simple rectangular prism to a complex three-dimensional shape with protrusions. This parameter change increases the cell's volume and capacity while maintaining compatibility with the constrained module case dimensions, allowing adequate range without increasing overall size.
Solution Approach 2:
By adding protrusions in the third dimension that extend into empty spaces, the battery cell increases its effective volume within the constrained module case. This dimensional utilization allows higher capacity packing without exceeding the maximum module case size required by vehicle design specifications.
3Stability of the object's composition
If empty spaces are left between mounting parts for secure attachment, then the mounting structure is stable, but the battery cell capacity is reduced due to unused space
Solution Approach 1:
The battery cell's protrusions are nested within the empty spaces between mounting parts, allowing the cell to occupy these previously wasted regions. This nesting maintains the mounting structure's stability by preserving the spacing and attachment points, while simultaneously increasing battery capacity by utilizing the interstitial volume.
Solution Approach 2:
The battery cell extends into the empty spaces between mounting parts through three-dimensional protrusions, converting previously unused volume into productive capacity. This dimensional utilization increases capacity while maintaining the mounting structure's stability, as the protrusions are positioned to fit within the available interstitial spaces without interfering with attachment points.
Data Source
AI summary
A battery cell accommodated in a module case of a battery module according to an embodiment of the present disclosure, is characterized in that at least one of the battery cell is included and accommodated in the module case, and has a shape corresponding to internal space of the module case so as to prevent formation of dead space in the module case.