Battery Pack Frame Rib Nesting for Capacity Expansion
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Solution Overview
Problem
The limited capacity of battery packs in portable computers restricts their operating hours and usage, as they are dependent on a power source stored in a battery pack, which is not sufficient for extended use without recharging.
Innovation Solution
A battery pack design featuring a frame with a main frame and ribs that accommodate multiple battery cells, a protection circuit module (PCM) connected to thermal sensors, and a pouch with side-wing units and terrace units formed by fusion welding, allowing for increased capacity and efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the battery pack capacity is increased to extend operating hours, then the duration of action is improved, but the volume and weight of the battery pack increase
Solution Approach 1:
The battery pack is divided into multiple battery cells (first battery cell, second battery cell, etc.) that are arranged in series or parallel configurations. This segmentation allows the total capacity to be increased by adding more cells rather than enlarging a single cell, optimizing the volume utilization within the battery pack housing.
Solution Approach 2:
The battery cells are nested within the frame structure, with each cell containing an electrode assembly that is tightly packed. The extension units of the pouch are inserted into insertion units formed by bending the ribs, creating a nested arrangement that maximizes space utilization and reduces overall volume.
2Quantity of substance
If multiple battery cells are integrated to increase capacity, then the quantity of energy storage is improved, but the device complexity increases
Solution Approach 1:
Multiple battery cells are combined within a single frame structure, sharing common protective housing, thermal management system, and control electronics. The frame integrates support functions, thermal management channels, and structural protection for all cells, reducing the overall complexity compared to separate packaging for each cell.
Solution Approach 2:
The frame structure serves multiple functions simultaneously: mechanical support for battery cells, thermal management through integrated heat dissipation channels, structural protection, and housing for the protection circuit module. This multi-functionality reduces the need for separate components, thereby reducing overall device complexity.
3Reliability
If the battery pack design includes thermal management systems, then the reliability is improved, but the device complexity and volume increase
Solution Approach 1:
The thermal management system is merged with the frame structure, where the frame itself serves as a heat dissipation pathway. Thermal management channels are integrated into the frame's design, eliminating the need for separate thermal management components and reducing overall system complexity.
Solution Approach 2:
The battery pack design utilizes the natural thermal conduction properties of the frame and pouch materials to dissipate heat from the battery cells. The extension units and insertion units create thermal pathways that passively conduct heat away from the cells, reducing the need for active thermal management systems.
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 enhances the battery pack's capacity and thermal management, enabling longer operating hours and improved reliability by allowing multiple battery cells to be efficiently integrated within a compact frame while maintaining thermal protection.
Implementation Method 1
the pouch includes a side-wing unit pair, and a terrace unit formed by fusion welding
Data Source
AI summary
A battery pack is disclosed. In one aspect the battery pack includes a battery cell including an electrode assembly and a pouch that seals the electrode assembly and a frame that accommodates the battery cell, wherein the frame comprises i) a main frame that surrounds the battery cell and ii) a rib that crosses the main frame. The pouch includes i) a pair of side-wing units each having a shape substantially similar to a side surface of the battery cell and extending in a direction and ii) a terrace unit connected to the side-wing units. Each of the side-wing units includes an extension unit that extends on the terrace unit along the direction. The frame includes an insertion unit into which the extension unit is inserted, and the rib is located on the terrace unit. According to embodiments, the capacity of the battery pack increases.