Battery Module Protection Cover for Tight Cell Stack Assembly

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Solution Overview

Problem

Existing battery modules face challenges in tightly coupling a cell stack with a protection structure without damaging the cell stack, which is crucial for optimizing volume and ensuring safety in applications like electric vehicles.

Innovation Solution

A battery module design featuring a box-shaped frame with openings, side plates, and protection covers that include convex edges and adhesive injection holes, which accommodate pouch-type cells and prevent damage by covering stepped portions, ensuring easy assembly and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the protection structure is tightly coupled with the cell stack to optimize volume, then the volume efficiency is improved, but the cell stack may be damaged during assembly

Engineering Contradiction:

Improvevolume efficiencyVSAvoidcell damage

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

A protection cover is introduced as an intermediary component between the cell stack and the frame. The protection cover includes a convex edge that protrudes toward the cell stack to cover stepped portions on the cell surface, preventing the frame from directly contacting and damaging the cells during assembly while maintaining tight coupling for volume optimization.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the protection structure is designed with strong coupling to ensure safety, then the protection performance is improved, but the assembly process becomes more difficult

Engineering Contradiction:

Improveprotection performanceVSAvoidassembly difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The protection cover features a convex edge with a curved or rounded profile rather than sharp angles. This curved design allows the protection cover to bridge over stepped portions on the cell stack smoothly, providing robust protection while facilitating easier assembly by reducing stress concentration and preventing damage during the coupling process.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Stability of the object's composition

If the frame directly contacts the cell stack for secure mounting, then the structural stability is improved, but the cell stack may be damaged

Engineering Contradiction:

Improvestructural stabilityVSAvoidcell damage

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The protection structure is segmented into distinct components: the frame and the protection cover. The protection cover is separately positioned between the frame and the cell stack, allowing the frame to provide structural stability through secure mounting while the protection cover specifically prevents direct contact damage to the cells.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP3694017B1Battery module having protection structure for cell stack

Publication Date: 2026.04.01 LG ENERGY SOLUTION LTD

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AI summary

A battery module according to an embodiment includes: a cell structure configured by stacking a plurality of secondary battery cells; a frame including at least one opening and configured to accommodate the cell structure in an inner space thereof through the opening; and a side plate covering the opening and including a protection cover disposed between the cell structure and the frame to cover the cell structure, wherein the protection cover may include a convex edge toward the inside of the cell structure.