Battery Pack With Composite Case Reducing Assembly Complexity
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Solution Overview
Problem
The manufacturing cost and complexity of multiple series/parallel battery packs increase due to the need for multiple components and high contact resistance between electrode assemblies, which are not effectively addressed by existing technologies.
Innovation Solution
A battery pack design featuring a lower case with internal and external plastic layers and a metal interlayer, along with an upper case, that accommodates electrode assemblies in cell compartments, minimizes contact resistance and reduces component count through electrical connections and a sealed structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple secondary batteries are connected in series and parallel to form a battery pack, then the battery capacity and power are improved, but the manufacturing cost and device complexity increase due to the need for multiple components and assembly processes
Solution Approach 1:
The patent combines multiple electrode assemblies into a single integrated battery pack structure with a unified case and shared electrolyte system. The case integrates multiple cell compartments within one housing, eliminating the need for separate battery units and reducing assembly complexity while maintaining high power output through proper series/parallel configuration of the electrode assemblies.
Solution Approach 2:
The case structure serves multiple functions simultaneously: it provides mechanical housing, contains the electrolyte, establishes electrical connections between electrode assemblies, and manages thermal conditions. This multi-functionality reduces the number of separate components needed, lowering manufacturing cost and assembly complexity while supporting high power battery pack configurations.
2Power
If multiple secondary batteries are connected in series and parallel to form a battery pack, then the battery capacity and power are improved, but the manufacturing cost increases due to the need for multiple components
Solution Approach 1:
The patent merges multiple battery functions into a single integrated case structure that houses multiple electrode assemblies, electrolyte, and connection systems. This consolidation reduces the total number of discrete components that need to be manufactured and assembled, thereby lowering manufacturing costs while maintaining the ability to achieve high power through series/parallel electrode assembly configurations.
3Strength
If a metal layer is added between internal and external plastic layers in the case, then the mechanical strength is improved, but the weight of the battery pack increases
Solution Approach 1:
The case employs a composite structure with plastic layers providing corrosion resistance and chemical stability, while a metal interlayer enhances mechanical strength and structural rigidity. This composite material approach optimizes the strength-to-weight ratio by combining materials with complementary properties, achieving high structural strength without excessive weight gain.
Data Source
AI summary
A battery pack including a plurality of electrode assemblies, a lower case including a plurality of cell compartments accommodating the plurality of electrode assemblies, and an upper case on the lower case at a top opening of the lower case, wherein each of the upper case and the lower case is includes a metal layer interposed between an internal layer and an external layer, the internal layer and the external layer being made of a plastic material.