Cell-to-Pack Battery Assembly With Pressure-Fixed Cooling Layers
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Solution Overview
Problem
The modular design of battery packs faces challenges in connectivity, structural integrity, weight, and cost efficiency, with increased failure points and electrical hazards, limited space utilization, and high manufacturing costs.
Innovation Solution
A method and apparatus for assembling energy storage packs by stacking energy storage members and cooling members alternately inside a frame structure, applying pressure to fixate them, dispensing a filler, and allowing it to cure, eliminating the need for preassembled modules and improving contact and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modular design with preassembled battery modules is used, then assembly flexibility and scalability are improved, but device complexity and manufacturing cost increase due to proliferation of connectors and structural components
Solution Approach 1:
The patent merges individual battery cells directly into the pack structure without preassembling them into separate modules. This eliminates the need for module connectors and structural components, reducing device complexity while maintaining assembly flexibility through direct cell-to-pack integration
2Ease of manufacture
If extensive connecting cables and structural components are used for modular assembly, then module integration is achieved, but weight increases significantly
Solution Approach 1:
The patent combines battery cells directly into the pack structure, eliminating the need for extensive connecting cables and module structural components. This direct integration approach maintains ease of manufacture while significantly reducing the overall weight of the energy storage pack
3Manufacturing precision
If modular battery modules with preassembled components are used, then manufacturing standardization is improved, but manufacturing cost increases due to complex integrating mechanisms
Solution Approach 1:
The patent merges battery cells directly into the pack structure, eliminating complex module integration mechanisms. This approach maintains assembly standardization through consistent direct-placement procedures while reducing manufacturing costs by eliminating expensive connectors, cables, and module structural components
4Ease of operation
If space is allocated for connectors and structural components in modular design, then module assembly is facilitated, but space utilization for energy storage decreases
Solution Approach 1:
The patent merges battery cells directly into the pack structure without allocating space for module connectors and structural components. This direct integration approach maintains assembly facilitation through simplified placement procedures while maximizing space utilization for energy storage by eliminating non-storage volume
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
This approach reduces assembly steps, weight, and costs while enhancing cooling capacity, mechanical and thermal contact, and overall performance, leading to a more compact and efficient energy storage pack.
Implementation Method 1
a filler is dispensed inside the frame structure, wherein at least the plurality of energy storage members and the plurality of cooling members are fixated in the predefined assembling position; and the assembling pressure is released after a predetermined curing time and/or curing condition of the filler
Data Source
AI summary
A method for assembling an energy storage pack, the method comprising providing the energy storage pack having a frame structure, a plurality of energy storage members and a plurality of cooling members for cooling the plurality of energy storage members; applying an assembling pressure on at least one side of the energy storage pack for at least temporarily fixating at least the plurality of energy storage members and the plurality of cooling members in a predefined assembling position; dispensing a filler inside the frame structure, when at least the plurality of energy storage members and the plurality of cooling members are fixated in the predefined assembling position; and releasing the assembling pressure to obtain the assembled energy storage pack.