Pouch Cell Battery Pack Assembly Without a Module Case
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Solution Overview
Problem
Conventional battery packs face challenges with energy density, assemblability, cooling efficiency, and thermal safety due to modularization, which can lead to increased volume, reduced space, and vulnerability to thermal events such as thermal runaway and explosions.
Innovation Solution
A battery pack design that includes pouch-type battery cells with a busbar frame assembly and cell covers that surround and support the cells, allowing direct stacking without a module case, enhancing energy density and cooling efficiency while providing improved thermal safety through effective heat dissipation and flame propagation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are modularized by accommodating them inside a module case, then assemblability is improved, but energy density is reduced due to increased volume and reduced space
Solution Approach 1:
The invention extracts and eliminates the module case from the conventional battery pack structure. By removing this intermediate component, battery cells are directly accommodated in the pack case, thereby eliminating the volume occupied by the module case and increasing the space available for battery cells, which directly improves energy density while maintaining assemblability through direct cell-to-pack-case integration.
Solution Approach 2:
The invention applies a nested structure where battery cells are directly placed within the pack case without an intermediate module case. This eliminates the hierarchical module level and creates a more compact nested arrangement, maximizing space utilization and energy density while preserving manufacturing ease through simplified direct integration.
2Ease of manufacture
If battery cells are modularized by accommodating them inside a module case, then assemblability is improved, but cooling efficiency is reduced due to complicated cooling structure
Solution Approach 1:
The invention extracts and removes the module case that complicated the cooling structure. By directly accommodating battery cells in the pack case, the cooling system can be simplified with direct thermal pathways from cells to cooling plates, eliminating the thermal resistance and structural complexity introduced by the module case while maintaining easy assembly.
3Stability of the object's composition
If a module case is used to accommodate battery cells, then device structure is more complete, but volume is unnecessarily increased
Solution Approach 1:
The invention extracts and eliminates the module case from the battery pack structure. By directly accommodating battery cells in the pack case, the overall volume is reduced while maintaining structural stability through direct cell-to-pack-case integration and appropriate positioning structures within the pack case.
4Ease of manufacture
If conventional battery packs are designed with module cases, then manufacturing process is standardized, but manufacturing process becomes complicated
Solution Approach 1:
The invention extracts and removes the module case from the manufacturing process. By directly accommodating battery cells in the pack case, the manufacturing process is simplified from a multi-stage modular assembly process to a more direct integration process, reducing the number of assembly steps and overall process complexity while maintaining standardization benefits.
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 improves energy density, assemblability, and thermal safety by eliminating the need for a module case, enhancing cooling performance, and effectively preventing thermal runaway and explosions by directing heat and gas discharge, thus ensuring safer battery packs and modules.
Implementation Method 1
a cell cover which is provided to surround at least partially at least some of the pouch-type battery cells
Implementation Method 2
If thermal runaway, ignition, or explosion occurs in some cells within any one battery module, the generated high-temperature gas, flame, or high-temperature internal material may be ejected and thermally propagated to other adjacent battery modules
Data Source
AI summary
Disclosed herein are a battery pack, a battery module, and a vehicle including the same. A battery pack according to one aspect of the present disclosure can includes a plurality of pouch-type battery cells each having an electrode lead, a busbar frame assembly coupled to at least some of the electrode leads of the plurality of pouch-type battery cells, and a cell cover provided to at least partially surround at least some of the pouch-type battery cells among the plurality of pouch-type battery cells. An end of the cell cover can be inserted into the busbar frame assembly.