Cell-to-Pack Battery Structure for Swelling and Vibration Stability
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Solution Overview
Problem
Existing battery packs face challenges in achieving high energy density and structural stability due to the use of module housings, which occupy space and reduce energy capacity, and require secure mounting of battery cells to prevent movement and swelling during impact or vibration.
Innovation Solution
A cell-to-pack type battery pack design featuring a cell unit group with compression pads and surface pressure providing walls, guided by guide pins in a pack case, which securely confines battery cells and suppresses swelling through compression and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If module housing is used to accommodate battery cells, then structural stability is improved, but energy density per unit volume deteriorates due to dead space and housing weight
Solution Approach 1:
The patent removes the module housing from the battery pack structure, transitioning from a module-level packaging approach to a cell-level packaging approach. This extraction of the intermediate housing layer eliminates dead space and reduces overall pack volume, thereby improving energy density while maintaining structural stability through direct cell mounting on the tray.
Solution Approach 2:
The patent merges the functions of the module housing and the pack tray into a single integrated structure. By directly mounting battery cells on the pack tray without intermediate module housings, the design combines structural support and cell accommodation functions into one component, eliminating wasted space and improving volumetric energy density.
2Quantity of substance
If module housing is omitted in cell to pack design, then energy density is improved, but structural stability against impact or vibration deteriorates
Solution Approach 1:
The patent applies local quality by providing targeted structural reinforcement at specific locations where battery cells are mounted. The pack tray includes strengthened mounting areas and positioning structures that locally enhance structural stability against impact and vibration, while the overall pack volume is maximized by eliminating the module housing.
Solution Approach 2:
The patent implements preliminary anti-action by designing the pack tray with pre-integrated strengthening structures and positioning features that proactively counteract impact and vibration forces before they can cause damage. The tray includes reinforced ribs, mounting brackets, and cell positioning structures that are built-in from the design stage to prevent structural failure under external forces.
3Device complexity
If battery cells are directly mounted in pack tray, then manufacturing complexity is reduced, but difficulty in preventing cell movement and swelling increases
Solution Approach 1:
The pack tray is designed with multi-functionality, serving both as the structural base and as the cell mounting platform with integrated positioning and securing features. The tray includes built-in cell positioning structures, mounting holes, and reinforcement features that perform multiple functions simultaneously, simplifying the manufacturing process while ensuring proper cell placement and securing.
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 allows for higher energy capacity and improved structural stability against vibration and impact, preventing performance degradation by securely mounting battery cells and mitigating swelling.
Implementation Method 1
a pair of surface pressure providing walls configured to compress the plurality of cell units and the compression pads
Implementation Method 2
the pack case comprises at least one guide pin which protrudes at a preset location of the bottom plate and is inserted into the pin insertion portion to guide a position of the surface pressure providing wall
Data Source
AI summary
A battery pack according to the present disclosure includes a cell unit group comprising a plurality of cell units stacked; a compression pad attached to at least one side of each of the cell units; and a pair of surface pressure providing walls configured to compress the plurality of cell units and the compression pads; and a pack case including a bottom plate and configured to accommodate the cell unit group, wherein each surface pressure providing wall has a pin insertion portion at a lower end of the surface pressure providing wall, the pin insertion portion being empty space exposed upwards from a lower surface of the lower end, and wherein the pack case comprises at least one guide pin which protrudes from the bottom plate and is inserted into the pin insertion portion to guide a position of the surface pressure providing wall.