CTP Battery Pack Zigzag Cell Welding Without Busbars
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Solution Overview
Problem
Conventional battery packs have low manufacturing efficiency, inefficient use of space, increased weight due to separate modules and busbars, and require additional parts for insulation and electrical connections.
Innovation Solution
A CTP (cell-to-pack) type high energy density battery pack is designed where pouch-shaped battery cells are stacked in series in a zigzag fashion, with internal connection members including insulation covers and sensing members, eliminating the need for a separate busbar and module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate battery module is used as an intermediate part, then battery cells can be organized and connected, but space is wasted and weight is increased
Solution Approach 1:
The invention extracts and eliminates the separate battery module as an intermediate component. Battery cells are directly connected and fixed to the support frame without requiring a module housing, thereby removing the unnecessary structural layer that adds weight while still maintaining proper cell organization and connection.
Solution Approach 2:
The invention merges the functions of the battery module housing and the battery pack structure into a single integrated design. The support frame directly holds multiple battery cells and provides structural support, combining what were previously separate components (module housing + pack structure) into one unified system that reduces overall weight.
2Ease of manufacture
If a separate battery module is used as an intermediate part, then battery cells can be organized and connected, but space efficiency is reduced
Solution Approach 1:
The separate battery module housing is extracted and removed from the system. Battery cells are directly mounted on the support frame, eliminating the module housing that previously occupied space. This direct mounting approach maximizes the usable space within the battery pack while maintaining proper cell organization and electrical connections.
Solution Approach 2:
The support frame simultaneously serves as both the structural support and the mounting platform for battery cells, merging what were previously separate functions (module housing + structural frame). This integration eliminates the space that would have been occupied by the module housing while maintaining all necessary structural and organizational functions.
3Reliability
If a busbar is used to connect battery cells, then electrical connection is achieved, but additional space and parts for insulation are required
Solution Approach 1:
The busbar component is extracted and removed from the system. Instead of using a separate busbar for electrical connections, the invention uses direct welding between battery cell terminals, eliminating the need for busbars and their associated insulation components, thereby reducing part count and structural complexity.
Solution Approach 2:
The electrical connection function is merged directly into the battery cell assembly process through welding. The support frame and battery cell mounts are designed to facilitate direct welding connections between cells, combining the electrical connection function with the structural mounting function, thereby eliminating the need for separate busbars and insulation parts.
4Ease of manufacture
If conventional battery pack manufacturing steps are used (cell manufacturing, module manufacturing, pack manufacturing), then battery assembly is achieved, but manufacturing efficiency is low
Solution Approach 1:
The intermediate battery module manufacturing step is extracted and removed from the production process. Battery cells are directly assembled and connected to the support frame in a simplified two-step process (cell assembly + direct connection), eliminating the separate module manufacturing step and significantly improving manufacturing efficiency and productivity.
Solution Approach 2:
The module manufacturing and pack manufacturing steps are merged into a single integrated process. Battery cells are directly mounted and connected to the support frame structure in one operation, combining what were previously separate manufacturing stages into a unified process that reduces complexity and improves manufacturing efficiency.
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
This design enhances manufacturing efficiency, optimizes space usage, reduces weight, and simplifies the assembly process by eliminating the need for a separate busbar and module, resulting in a high energy storage capacity per unit of space.
Implementation Method 1
a weld is formed at a part at which a first electrode lead and a second electrode lead protruding respectively from a first battery cell and a second battery cell
Data Source
AI summary
Disclosed is a battery pack including a battery cell stack, an internal connection member coupled to opposite ends of the battery cell stack from which the electrode leads protrude, and a pack frame configured to receive the battery cell stack and the internal connection member. A weld is formed at a part at which a first electrode lead and a second electrode lead protruding respectively from a first battery cell and a second battery cell of the battery cell stack, which neighbor each other, are bent in different directions and overlap each other. All battery cells constituting the battery cell stack are connected to each other in series in a zigzag fashion, and the internal connection member includes an insulation cover configured to isolate the electrode leads from the outside and a sensing member electrically connected to the weld.