Battery Pack Cell Cover Structure for High-Density Pouch Cell Mounting

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Solution Overview

Problem

Existing battery pack manufacturing technologies result in increased weight and volume, reduced energy density, and difficulties in handling and mounting large numbers of battery cells, leading to potential damage during the manufacturing process.

Innovation Solution

A battery pack design featuring a battery assembly with cell units that include pouch type battery cells partially covered by a simplified cell cover structure, which is mounted directly to a pack case, reducing the need for separate module cases and facilitating easier handling and mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery cells are housed in a box-shaped metal case to configure a battery module, then the battery cells are protected and organized, but the overall weight and volume of the battery pack increases and energy density decreases

Engineering Contradiction:

Improvebattery cell protectionVSAvoidbattery pack weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention extracts and eliminates the intermediate battery module case from the traditional battery pack structure. Battery cells are mounted directly onto the pack case without being enclosed in separate module cases, thereby removing unnecessary weight and volume while maintaining cell protection through direct mounting structures and sealants.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the battery module case function directly into the pack case structure. Instead of having separate module cases enclosing battery cells, the pack case itself provides the structural support and protection, integrating multiple functions into a single component to reduce overall weight and volume.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If battery cells are housed in a box-shaped metal case to configure a battery module, then the battery cells are protected and organized, but the overall volume of the battery pack increases and energy density decreases

Engineering Contradiction:

Improvebattery cell protectionVSAvoidbattery pack volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The invention extracts and eliminates the intermediate battery module case from the traditional battery pack structure. Battery cells are mounted directly onto the pack case without being enclosed in separate module cases, thereby removing unnecessary volume while maintaining cell protection through direct mounting structures and sealants.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

3Quantity of substance

If a large number of pouch type battery cells are mounted directly to the pack case, then energy density increases, but handling and mounting becomes difficult and battery cells may be damaged

Engineering Contradiction:

Improvebattery cell densityVSAvoidhandling and mounting ease

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The invention segments battery cells into groups of three, with each group enclosed in a simplified cell cover structure. This segmentation makes handling easier while maintaining high cell density. The cell cover acts as a lightweight protective enclosure that facilitates manageable handling without requiring heavy module cases.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces a simplified cell cover as an intermediary structure between the battery cells and the pack case. This cell cover provides lightweight protection and facilitates handling during mounting, serving as a mediator that enables easy manufacture while maintaining high cell density. The cell cover includes features like blocking parts that prevent cell removal and ensure proper positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Quantity of substance

If a large number of pouch type battery cells are mounted directly to the pack case, then energy density increases, but battery cells may be damaged during the mounting process

Engineering Contradiction:

Improvebattery cell densityVSAvoidbattery cell integrity

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The invention provides beforehand cushioning by enclosing battery cells in simplified cell covers before mounting to the pack case. These cell covers act as protective enclosures that cushion and protect the soft pouch type battery cells during handling and mounting processes, preventing damage while maintaining high cell density.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250030108A1Battery Pack and Device Including the Same

Publication Date: 2025.01.23 LG ENERGY SOLUTION LTD

AI summary

A battery pack includes a battery assembly including a plurality of cell units, and a pack case that houses the battery assembly in an inner space, wherein each cell unit includes at least one battery cell and a cell cover that partially covers the at least one battery cell, and wherein the cell cover comprises a first cover part that covers one side surface of the at least one battery cell, a second cover part that covers the other side surface of the at least one battery cell, a third cover part that connects one end of the first cover part and one end of the second cover part, and blocking parts that are respectively formed at the other end of the first cover part and the other end of the second cover part, and block removal of the at least one battery cell.