Battery Cell Cover Structure for Dense and Stable Pack Assembly
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Solution Overview
Problem
Existing battery assemblies face challenges in maximizing energy density and stability due to structural limitations and manufacturing inefficiencies, particularly when increasing the number of battery cells.
Innovation Solution
A battery assembly design that includes a cell cover covering tab portions, a busbar assembly, and a side member with recessed portions and coupling features, along with a fastening mechanism to stabilize and connect components, enhancing structural integrity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If more battery cells are grouped together to increase capacity, then energy density improves, but structural stability deteriorates due to increased complexity of fixation components
Solution Approach 1:
The cell cover integrates multiple functions into a single component: it covers the tab portion, provides coupling portions for fixation to the side member, and includes protecting portions for battery cell support. This merging of functions reduces the number of separate fixation components while maintaining structural stability with increased battery cell quantity.
Solution Approach 2:
The side member serves multiple purposes: it provides structural support, receives coupling portions from cell covers for fixation, and includes recessed portions for accommodating busbar assemblies. This multi-functionality allows the structure to maintain stability while accommodating more battery cells without adding proportional fixation complexity.
2Quantity of substance
If fixation components are minimized to improve energy density, then volume ratio increases, but manufacturing precision requirements worsen due to reduced tolerance for assembly errors
Solution Approach 1:
The coupling portion is positioned within a recessed portion of the side member, creating a nested arrangement where the cell cover fits into the side member structure. This nesting provides self-alignment during assembly, reducing tolerance requirements and simplifying manufacturing while maximizing volume utilization.
Solution Approach 2:
The coupling portion extends in the height direction of the accommodating case, utilizing vertical space rather than horizontal space for fixation. This dimensional change allows fixation without increasing the footprint area, thereby improving volume ratio while maintaining assembly precision through the vertical coupling mechanism.
3Device complexity
If cell cover structure is simplified to reduce components, then device complexity decreases, but reliability worsens due to reduced protection and fixation capability
Solution Approach 1:
The cell cover is segmented into distinct functional regions: a covering portion for tab protection, coupling portions for fixation to the side member, and protecting portions for battery cell support. This segmentation allows each region to perform its specific function effectively, maintaining reliability while keeping the overall structure simple and integrated.
Data Source
AI summary
A battery assembly of the present disclosure includes: a plurality of battery cells disposed along a preset stacking direction; a cell cover covering a tab portion protruding from one side of at least one battery cell among the plurality of battery cells; an accommodating case accommodating the plurality of battery cells; and a side member extending from the accommodating case toward the plurality of battery cells, wherein at least a part of the cell cover is positioned on the upper portion of the side member and supported by the side member.