CTP Battery Pack Slot-and-Band Structure for Impact and Gas Control
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Solution Overview
Problem
Existing battery pack designs face issues with increased weight and volume, reduced energy density, and inadequate control of gas discharge and cell damage due to external impact or vibration, particularly in high-density battery modules.
Innovation Solution
A battery pack design using a cell-to-pack (CTP) method where battery units are directly mounted on a tray without a separate case, featuring a tray with slots and fixing bands, cell covers, and support bands to stabilize and protect the battery cells, along with a pocket to collect discharged materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are densely arranged in a narrow space to increase energy density, then energy density is improved, but the risk of damage to battery cells due to external impact or vibration increases
Solution Approach 1:
The patent applies beforehand cushioning by providing a battery module case that encloses the battery cells before they are installed in the battery pack. This case acts as a protective cushion that absorbs external impacts and vibrations, preventing damage to the battery cells while allowing dense arrangement for high energy density.
Solution Approach 2:
The patent uses the battery module case as an intermediary between the battery cells and the external environment. This intermediate structure protects the battery cells from direct exposure to external impacts and vibrations, enabling dense cell arrangement without compromising reliability.
2Quantity of substance
If battery cells are directly accommodated in a battery pack case to increase energy density, then energy density is improved, but the discharge direction of gas, flame, or foreign material during thermal runaway cannot be appropriately controlled
Solution Approach 1:
The patent segments the battery pack into multiple battery modules, each with its own enclosed case. This segmentation allows each module to independently control the discharge direction of gas and flame during thermal runaway, preventing uncontrolled propagation while maintaining high energy density through direct accommodation of cells in the pack case.
Solution Approach 2:
The patent converts the harmful effect of gas and flame discharge during thermal runaway into a controlled process by designing the battery module case with specific discharge paths. This allows the harmful substances to be directed away from critical components, transforming an uncontrolled hazard into a managed safety feature.
3Reliability
If a box-shaped metal case is used to accommodate battery cells forming a battery module, then protection of battery cells is improved, but the weight and volume of the entire battery pack increase
Solution Approach 1:
The patent merges the battery module case with the battery pack case, eliminating the need for separate enclosing structures. This integration reduces the overall weight and volume of the battery pack while maintaining adequate protection for the battery cells through the combined structural design.
Solution Approach 2:
The patent extracts the excessive protective structure from the traditional box-shaped metal case design. By removing unnecessary material and simplifying the enclosure to only the essential protective functions, the weight and volume are reduced while maintaining cell protection through the integrated case structure.
Data Source
AI summary
Provided are a battery pack and a battery pack manufacturing method. A battery pack according to an aspect of the present disclosure includes a battery assembly including a plurality of battery units which are stacked on each other, each of the plurality of battery units including at least one battery cell, a tray including a plurality of first slots configured to allow the battery assembly to be inserted, and at least one fixing band coupled to an inlet of a first slot into which the battery assembly is inserted from among the plurality of first slots, to fix the battery assembly to the first slot into which the battery assembly is inserted.