Battery Pack Cell Stacking Frame for Higher Energy Density
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Solution Overview
Problem
Rechargeable battery packs with modules have limitations in energy capacity, necessitating the development of a pack that directly assembles battery cells without a module to maximize energy density.
Innovation Solution
A rechargeable battery pack design that stacks battery cells using a center frame, side frames, and end frames, with a pressurizing body to compress the cell stack, enhancing energy density and allowing for various cell sizes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rechargeable battery modules are used to assemble battery packs, then the battery pack can be manufactured with standardized modules, but the energy capacity and energy density are limited
Solution Approach 1:
The patent extracts and removes the battery module intermediate structure from the assembly. Instead of using pre-assembled battery modules, the invention directly assembles individual battery cells into the battery pack, eliminating the module layer and enabling higher energy capacity while reducing structural complexity.
Solution Approach 2:
The patent segments the battery pack assembly into individual battery cells that can be directly arranged and connected without module groupings. This segmentation allows flexible configuration of cells to maximize energy capacity while simplifying the overall structure by removing module boundaries.
2Quantity of substance
If battery cells are directly stacked without modules, then energy density is maximized, but mechanical stability and structural support become challenging
Solution Approach 1:
The frame structure in the patent serves multiple functions simultaneously: it provides mechanical support for direct cell stacking, enables thermal management through integrated channels, and facilitates electrical connections. This multi-functionality maintains structural stability while maximizing energy density without requiring separate module components.
Solution Approach 2:
The patent merges the structural support function, thermal management function, and electrical connection function into a single integrated frame structure. This consolidation eliminates the need for separate module housings and internal support structures, enabling direct cell stacking while maintaining mechanical stability.
3Quantity of substance
If various sizes of battery cells are used to maximize energy capacity, then pack energy is increased, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The patent applies local quality by providing specifically designed positioning structures and mounting features at different locations within the frame for different cell sizes. This allows various sized battery cells to be precisely positioned and assembled without requiring uniform cell dimensions, thereby maximizing pack energy while maintaining manufacturing precision.
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 effectively increases pack energy density by directly assembling battery cells, allowing for customizable cell sizes and improved mechanical stability through the use of a pressurizing body.
Implementation Method 1
a compressing force generator supported on the end frame by screwing the second plane portion and causing the first plane portion to press the cell stack
Data Source
AI summary
A rechargeable battery pack that maximizes pack energy density by stacking battery cells. A rechargeable battery pack includes a center frame having a first bottom and a first side wall and supporting the cell stack, a first side frame and a second side frame having a second bottom and a second side wall and coupled to the center frame in a second direction crossing the first direction and supporting a cell narrow side of the cell stack, and a first end frame and a second end frame coupled to both ends of the center frame, the first side frame, and the second side frame in the first direction to support a cell wide side of the cell stack.