Battery Pack Binding Bar Structure for Compact Cell Stacking
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Solution Overview
Problem
Existing battery assemblies struggle to achieve a high volume energy density while maintaining a reduced size, particularly in the height dimension.
Innovation Solution
A battery assembly design featuring first and second binding bars with cushion regions and a cooling device, which securely fasten and stabilize battery cells while allowing for sliding expansion, using hollow resin-molded cushions and a coolant passage for enhanced stability and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If battery cells are stacked tightly to reduce height, then the size is reduced, but the volume energy density decreases due to tolerance accumulation and inability to accommodate thermal expansion
Solution Approach 1:
The binding bar is segmented into multiple functional regions: pressing portions for applying pressure, cushion portions for absorbing tolerance and expansion, and cooling device integration. This segmentation allows each region to perform its specific function while working together to resolve the contradiction between compact height and energy density
Solution Approach 2:
Cushion portions are pre-installed at corner portions of battery cells before stacking. These cushions absorb position tolerances and thermal expansion in advance, preventing gaps and instability that would otherwise require additional spacing, thereby maintaining high volume energy density while enabling reduced height
2Stability of the object's composition
If binding structures are added to stabilize battery cells, then stability is improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single binding bar component: mechanical binding, cushioning for tolerance absorption, and cooling device integration. This merging reduces the number of separate components and assembly steps, improving stability without significantly increasing device complexity
Solution Approach 2:
The binding bar serves multiple purposes simultaneously: it binds battery cells together, provides cushioning at corner portions, houses cooling devices, and maintains electrical insulation. This multi-functionality achieves high stability while minimizing the increase in structural complexity
3Volume of stationary object
If cushion portions are added at corner portions, then volume energy density is improved, but manufacturing complexity increases
Solution Approach 1:
Cushion portions are strategically placed only at corner portions of battery cells where tolerance accumulation and thermal expansion occur most. This localized approach provides the necessary cushioning for high volume energy density while minimizing the overall amount of additional material and manufacturing complexity
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
The design achieves a high volume energy density with reduced size, particularly in height, while maintaining electrical connectivity and stability under thermal expansion, reducing component count and material strength requirements.
Implementation Method 1
anode-side cushion and cathode-side cushion respectively having a cooling device allowing a coolant to pass through
Implementation Method 2
a cooling device allowing a coolant to pass through
Implementation Method 3
resin-molded cushion portions... By fastening and fixing the first binding bar and the second binding bar together, the electrode-terminal-side cushion is pressed against a side of the corner portion
Data Source
AI summary
The present battery assembly includes: a first binding bar provided to cover a side of each of a plurality of battery cells on which an electrode terminal is disposed; a second binding bar provided to cover a side of each of the battery cells opposite to the side on which the electrode terminal is disposed; and an electrode-terminal-side cushion provided at at least one corner portion of the battery cell located, on the side on which the electrode terminal is disposed, in a direction intersecting a direction in which the battery cells each including the first side surface on which the electrode terminal is disposed are stacked, so as to extend along the direction in which the battery cells are stacked, wherein the first binding bar and the second binding bar are fastened and fixed.