Integrated CTP Battery Cover for Fewer Pack Components

Solution Overview

Problem

The existing cell-to-pack (CTP) battery structure requires separate endplates and top covers, increasing the number of components and assembly processes, which complicates manufacturing and raises costs.

Innovation Solution

A CTP battery design featuring an integrated cover that encompasses the upper and side surfaces of the cell assembly, along with clamps supported on the bottom surface, reduces the number of components and assembly processes by integrating multiple functions into a single component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate endplates and top cover are used in CTP battery structure, then the cell assembly can be properly surrounded and protected, but the number of components increases and assembly processes become more complex

Engineering Contradiction:

Improvecell assembly protectionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the endplate and top cover into a single integrated cover component. The integrated cover includes a top cover portion covering the upper surface of the cell assembly and side cover portions extending downward to cover the side surfaces, eliminating the need for separate endplates and reducing the number of components that need to be assembled.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated cover serves multiple functions simultaneously: it acts as both the top cover and the endplates, providing structural support, cell protection, and clamping surface formation. The side cover portions extend downward to perform the protective function previously requiring separate endplate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate endplates and top cover are used in CTP battery structure, then the cell assembly can be properly surrounded and protected, but the number of assembly processes increases

Engineering Contradiction:

Improvecell assembly protectionVSAvoidassembly process efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines the endplate and top cover into a single integrated cover component. The integrated cover includes a top cover portion covering the upper surface of the cell assembly and side cover portions extending downward to cover the side surfaces, eliminating the need for separate endplates and reducing the number of components that need to be assembled.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated cover is designed as a pre-formed single piece with side cover portions that already extend downward to the required position. This preliminary formation of the complete protective structure eliminates the need for subsequent assembly steps to attach separate endplates, streamlining the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If multiple separate components are used to surround cell assembly, then comprehensive protection is achieved, but manufacturing costs increase

Engineering Contradiction:

Improvecell assembly protectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the endplate and top cover into a single integrated cover component. The integrated cover includes a top cover portion covering the upper surface of the cell assembly and side cover portions extending downward to cover the side surfaces, eliminating the need for separate endplates and reducing the number of components that need to be assembled.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated cover serves multiple functions simultaneously: it acts as both the top cover and the endplates, providing structural support, cell protection, and clamping surface formation. The side cover portions extend downward to perform the protective function previously requiring separate endplate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250105426A1Cell-to-pack battery

Publication Date: 2025.03.27 HYUNDAI MOTOR CO LTD

AI summary

A cell-to-packet (CTP) battery has a simplified structure for surrounding a cell assembly, thereby reducing the number of components and the number of assembling and working processes. The CTP battery may include an integrated cover shaped to cover an upper surface and left and right surfaces of a cell assembly. The CTP battery may also include a clamp supported on a bottom surface of the cell assembly and connected between left and right panels of the integrated cover.