Cell-to-Pack Battery Assembly With Sealed Busbar Gas Venting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs face limitations in energy density, assembly complexity, cooling efficiency, and vulnerability to external impacts due to the use of module cases, stacking frames, and lack of effective sealing, which complicates manufacturing and compromises safety.
Innovation Solution
A battery pack design that eliminates module cases and stacking frames by using a cell cover to directly house battery cells, incorporating busbar assemblies with sealing members and cell covers to enhance stability, cooling, and control gas discharge, thereby improving energy density, assembly efficiency, and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If module cases and stacking frames are used to house battery cells, then assembly stability and protection are improved, but energy density decreases due to increased volume occupation by structural components
Solution Approach 1:
The patent removes module cases and stacking frames from the battery pack structure, extracting these unnecessary components that occupied valuable space. Battery cells are directly arranged and fixed within the pack case using minimal structural elements, thereby eliminating the volume consumption by module cases and stacking frames while maintaining assembly stability through direct cell-to-pack-case configuration.
Solution Approach 2:
The patent merges the functions of module cases and stacking frames into a simplified direct-fixation system. Instead of having separate module cases for housing and stacking frames for positioning, the design integrates these functions by directly mounting battery cells to the pack case structure, reducing the number of components and maximizing the space available for active battery materials.
2Strength
If module cases and stacking frames are used to house battery cells, then structural support and protection are improved, but device complexity increases due to multiple components and assembly steps
Solution Approach 1:
The patent extracts and removes module cases and stacking frames from the battery pack assembly, significantly reducing the number of components that need to be manufactured, procured, and assembled. This extraction simplifies the overall device structure while maintaining necessary structural support through direct cell mounting to the pack case.
Solution Approach 2:
The patent combines the structural support functions of module cases and stacking frames into a simplified direct-fixation system. By merging these separate structural elements into a unified approach where cells are directly mounted to the pack case, the design reduces assembly complexity while preserving the essential structural support and protection functions.
3Object-generated harmful factors
If conventional sealing structures are used in battery packs, then gas discharge control is insufficient, but safety improves with better thermal runaway prevention
Solution Approach 1:
The patent introduces sealing members as intermediary components between battery cells and the external environment. These sealing members are specifically positioned to control gas discharge pathways, allowing safe venting of gases generated during thermal runaway events while preventing uncontrolled gas release and flame propagation. The sealing members act as mediators that manage the harmful gas discharge while enhancing overall safety.
Solution Approach 2:
The patent implements preliminary sealing measures by installing sealing members in advance within the battery pack structure. These pre-positioned sealing components are designed to activate or become effective during thermal runaway events, controlling gas discharge pathways before uncontrolled gas release and flame propagation can occur, thereby preventing catastrophic failures.
Data Source
AI summary
A battery pack according to an embodiment of the present disclosure includes a plurality of battery cells stacked in one direction, a pack case that houses the battery cells in an inner space, a cell cover that at least partially surrounds at least a part of the plurality of battery cells in the inner space of the pack case, a busbar assembly that electrically connects the plurality of battery cells, a first sealing member mounted to the busbar assembly and a second sealing member mounted to the cell cover.