Convex-Edge Protection Cover for Damage-Free Cell Stack Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The challenge is to tightly couple a cell stack and a protection structure in a battery module without damaging the cell stack during manufacturing, while ensuring safe protection and optimal volume utilization in applications like electric vehicles.

Innovation Solution

A battery module design featuring a box-shaped frame with openings, side plates, and protection covers that include convex edges and adhesive injection holes to securely hold pouch-type battery cells, preventing damage and ensuring easy assembly and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the protection structure is tightly coupled with the cell stack to optimize volume, then volume utilization is improved, but the cell stack may be damaged during assembly

Engineering Contradiction:

Improvevolume utilizationVSAvoidcell damage

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

A protection cover is introduced as an intermediary component between the cell stack and the frame. The protection cover includes a convex distal edge that prevents direct contact and potential damage between the frame and the cell stack, while still allowing tight coupling for optimal volume utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protection cover is installed beforehand to cushion and protect the cell stack from potential damage during the assembly process. The convex distal edge of the protection cover acts as a buffer that prevents harmful contact between the frame and the cell stack.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If the protection structure is coupled to safely protect the cell stack, then protection reliability is improved, but the assembly process becomes more complex

Engineering Contradiction:

Improveprotection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protection cover is integrated with the frame structure, merging two components into a unified assembly. This reduces the number of separate parts and simplifies the assembly process while maintaining protection reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protection cover serves multiple functions: it protects the cell stack from damage, optimizes volume utilization, and simplifies the assembly process. This multi-functionality reduces the need for additional components and simplifies the overall assembly complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11811080B2Battery module having protection structure of cell stack

Publication Date: 2023.11.07 LG ENERGY SOLUTION LTD

AI summary

A battery module according to an embodiment includes: a cell structure configured by stacking a plurality of secondary battery cells; a frame including at least one opening and configured to accommodate the cell structure in an inner space thereof through the opening; and a side plate covering the opening and including a protection cover disposed between the cell structure and the frame to cover the cell structure, wherein the protection cover may include a convex edge toward the inside of the cell structure.