Cell-to-Pack Battery Assembly With Cell Covers for Stable Mounting
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Solution Overview
Problem
Conventional battery packs face issues of increased weight and volume, reduced energy density, and difficulty in handling and mounting multiple battery cells without damage, leading to higher manufacturing costs and potential cell damage during assembly.
Innovation Solution
A battery pack design featuring a cell-to-pack structure with cell units arranged vertically, covered by a cell cover and secured by a fixing unit, which includes a support plate and end cover to stabilize and simplify the mounting process, reducing weight and volume while preventing cell damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery modules with multiple battery cells inside module cases are used, then the battery pack structure is stable and easy to assemble, but the overall weight and volume increase, reducing energy density
Solution Approach 1:
The patent divides the battery pack into individual cell units, each comprising a battery cell and an integrated cell cover assembly. This segmentation eliminates the need for separate module cases while maintaining structural integrity through the cell cover that directly attaches to the pack case, thereby reducing overall weight and volume.
Solution Approach 2:
The cell cover is designed to cover and protect the battery cell, forming a nested structure where the cell cover encloses the cell. This nested design integrates protection and structural support functions into a single compact assembly, eliminating additional module case layers and reducing overall pack volume.
2Reliability
If conventional battery modules with module cases are used, then the battery pack structure is stable, but the volume increases, reducing energy density
Solution Approach 1:
The battery pack is segmented into discrete cell units with integrated cell covers that attach directly to the pack case. This eliminates the intermediate module case structure, reducing the volume required for structural support while maintaining stability through direct cell-to-pack mounting.
Solution Approach 2:
The cell cover acts as a thin protective shell that encloses the battery cell and provides structural support. This thin-film approach replaces bulky module cases, significantly reducing the volume occupied by protective and structural components.
3Weight of stationary object
If a large number of battery cells are directly attached to the pack case using cell-to-pack technology, then energy density increases, but handling and stacking becomes difficult, and there is a risk of cell damage during mounting
Solution Approach 1:
The cell cover is pre-assembled with the battery cell in a controlled manner before being mounted to the pack case. This preliminary assembly creates a stable, integrated unit that is easier to handle and stack during manufacturing, reducing the risk of cell damage while maintaining the cell-to-pack energy density benefits.
Solution Approach 2:
The cell cover serves as a protective cushion that surrounds the battery cell during handling and mounting operations. This pre-established protection reduces the risk of cell damage during assembly while enabling the direct cell-to-pack configuration that improves energy density.
4Volume of stationary object
If a large number of battery cells are directly attached to the pack case, then energy density increases, but the risk of cell damage during mounting increases
Solution Approach 1:
The cell cover is designed to surround and protect the battery cell before mounting to the pack case. This pre-established protective enclosure cushions the cell during handling and assembly operations, reducing the risk of damage while enabling the compact cell-to-pack configuration that improves energy density.
Solution Approach 2:
The cell cover functions as a flexible protective shell that encloses the battery cell, providing cushioning and protection during mounting operations. This thin-film protective structure reduces cell damage risk while maintaining the compact volume required for high energy density.
Data Source
AI summary
A battery pack according to an embodiment of the present invention includes a battery assembly including a plurality of cell units arranged side by side in one direction, and a pack case that houses the battery assembly in an inner space, wherein the cell unit includes at least one battery cell and a cell cover covering a part of the battery cell, and wherein the battery assembly penetrates through the cell cover to thereby restrict a relative movement of the plurality of cell units.