Battery Cell Insertion Layout for Dense Cell-to-Pack Assembly
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Solution Overview
Problem
Current battery pack manufacturing methods result in low volumetric energy density due to space being divided between cells and other mechanical components, leading to inefficient use of space and potential alignment issues during assembly, especially in large packs.
Innovation Solution
A battery pack assembly apparatus and method that directly assembles cells into a pack without modularization, using a cell gripper and guide to manage cell placement and insertion, ensuring proper alignment and maximizing cell density by inserting cells from the periphery towards the center with a last cell inserted through a spaced gap, and utilizing a guide film and air knife to prevent damage and secure alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cells are componentized into modules with mechanical strength-enhancing components, cooling components, and insulation components, then the structural integrity and cooling efficiency are improved, but the volumetric energy density decreases due to increased space occupation by non-active components
Solution Approach 1:
The patent merges the cell assembly directly into the battery pack housing without intermediate module structures. Multiple cells are arranged and fixed directly in the tray, eliminating separate module enclosures, covers, and inter-module components. This integration reduces the volume occupied by mechanical strength-enhancing components while maintaining structural integrity through direct cell-to-pack positioning.
Solution Approach 2:
The patent extracts the intermediate module structure from the battery assembly hierarchy. Instead of organizing cells into separate modules with their own enclosures and components, the design takes out the module level entirely and places cells directly into the pack housing, removing unnecessary mechanical components and increasing the proportion of space dedicated to active cell volume.
2Quantity of substance
If cells are arranged densely to maximize volumetric energy density, then the number of cells per pack increases, but alignment precision deteriorates due to cumulative positioning errors during assembly
Solution Approach 1:
The patent implements preliminary positioning features directly on the tray before cells are installed. The tray includes pre-formed positioning protrusions and corresponding recesses that guide cell placement. This preliminary action establishes precise reference points beforehand, ensuring that even when cells are densely packed, each cell maintains accurate alignment relative to its neighbors and the overall pack structure, preventing cumulative positioning errors.
3Quantity of substance
If a simplified cell-to-pack assembly method is used without module structures, then the volumetric energy density improves, but the difficulty of maintaining alignment during pressurization increases
Solution Approach 1:
The patent applies local quality by providing enhanced positioning features at critical locations within the tray. Specific areas have reinforced positioning structures, localized support elements, and targeted alignment features that provide extra stability during pressurization. This localized reinforcement maintains alignment precision in key areas without requiring complex structures throughout the entire assembly, balancing manufacturing ease with alignment maintenance.
Data Source
AI summary
An embodiment battery pack assembly apparatus includes a cell gripper configured to grip a battery cell and to move the battery cell in a first direction and a cell guide including a slider movable in a second direction perpendicular to the first direction, wherein the cell guide is configured to guide movement of the battery cell in the first direction.