Battery Pack Housing for Frameless Pouch Cell Mounting
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Solution Overview
Problem
Conventional pouch-type secondary batteries are prone to deformation and have flexible electrode leads, making them difficult to mount directly into a battery pack without a modular frame, which complicates the manufacturing process and requires additional structural support.
Innovation Solution
A battery pack design featuring a cell assembly with electrode leads connected via a bus bar assembly and cell support parts, which are coupled to a pack housing using guide rails and adhesive members, allowing for stable support and connection without a modular frame, eliminating the need for welding and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional pouch-type secondary battery is used, then the battery cell has flexibility and can be configured in various forms, but the battery cell is prone to deformation and requires a modular frame for mounting
Solution Approach 1:
The invention extracts and removes the modular frame from the battery pack structure. Instead of using a separate frame to hold the battery cells, the cells are directly mounted to the pack housing using adhesive members, eliminating the unnecessary structural component while maintaining cell support and stability.
Solution Approach 2:
The invention merges the functions of the modular frame with the pack housing. The pack housing is designed to directly support and position the battery cells through integrated mounting structures, combining the structural support function into a single unified component rather than requiring separate frame and housing elements.
2Stability of the object's composition
If a modular frame is used to support battery cells, then the battery cells are stable, but the manufacturing process becomes complicated
Solution Approach 1:
The modular frame is completely removed from the manufacturing process. Battery cells are directly adhered to the pack housing using adhesive members, eliminating the complex assembly steps required to attach cells to a separate frame structure and then assemble the frame into the pack.
Solution Approach 2:
The pack housing is pre-designed with integrated mounting features and positioning structures that guide battery cell placement. Adhesive members are pre-positioned on the housing, allowing battery cells to be directly mounted in their final positions during assembly, eliminating the need for separate frame assembly steps.
3Adaptability or versatility
If electrode leads are made flexible, then the battery cell has design flexibility, but the electrode leads are difficult to connect and require welding
Solution Approach 1:
The invention replaces the welding process with a mechanical connection system. Bus bar assemblies with pressing members mechanically clamp onto the flexible electrode leads, providing electrical connection through contact pressure rather than thermal welding, thereby simplifying the manufacturing process while maintaining lead flexibility.
Solution Approach 2:
The bus bar assembly acts as an intermediary component between the flexible electrode leads and the rigid electrical connection system. The bus bar with its pressing member provides a compliant connection interface that accommodates the flexibility of the electrode leads while establishing reliable electrical contact without requiring welding.
4Strength
If a modular frame is used, then the battery pack structure is complete, but additional structural support components are required
Solution Approach 1:
The modular frame component is extracted and removed from the battery pack structure. The pack housing is redesigned to provide all necessary structural support functions directly, eliminating the need for the separate frame component and reducing the total number of parts in the assembly.
Solution Approach 2:
The pack housing is designed to perform multiple functions simultaneously: it provides the external enclosure for the battery pack, serves as the structural support framework, and acts as the mounting surface for battery cells. This multi-functional design eliminates the need for dedicated frame structures that would otherwise be required for support.
Data Source
AI summary
Disclose herein is a battery pack for mounting a cell assembly including a plurality of battery cells to the battery pack without a modular frame.The battery pack can includes a cell assembly with a plurality of battery cells having electrode leads. A pack housing of the battery pack can accommodate the cell assembly therein. A bus bar assembly disposed on both sides of the cell assembly, can be coupled to the pack housing, and connected to the electrode leads of the plurality of battery cells.