CTP Battery Pack Crossbeam Layout for Cooling and Swelling Control
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Solution Overview
Problem
Conventional battery packs face challenges in terms of energy density, assembly complexity, cooling efficiency, and swelling control, particularly when using high-capacity battery cells like Pure Si and high SiO content cells.
Innovation Solution
A battery pack design featuring a battery cell assembly with a CTP (Cell To Pack) structure that includes a battery cell stack housed within a pack frame, utilizing sub-crossbeams on the side surfaces of the stack, spaced apart from the crossbeam, and a busbar frame for improved fixation and cooling, along with thermal resin layers and pad members for swelling control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a module case or stacking frame is used to house battery cells, then structural support and assembly are improved, but the volume occupied by components increases and energy density decreases
Solution Approach 1:
The patent integrates the stacking frame and module case into a unified CTP structure where the pack frame directly houses battery cells without separate module cases. The crossbeams serve dual purposes as both structural support elements and stacking fixtures, eliminating redundant components and maximizing battery cell volume occupancy.
Solution Approach 2:
The crossbeams are designed to perform multiple functions: providing structural support for the pack, serving as stacking fixtures for battery cells, and enabling assembly operations. This multi-functionality reduces the number of separate components needed, thereby increasing the volume available for battery cells and improving energy density.
2Reliability
If assembly tolerance is secured for components like module case or stacking frame, then manufacturing reliability is improved, but the receiving space for battery cells is reduced
Solution Approach 1:
The patent divides the pack frame into modular sections with crossbeams positioned at specific intervals. This segmentation allows for localized tolerance management at each crossbeam-battery cell interface while maintaining overall structural integrity, reducing the cumulative tolerance stack-up that would otherwise consume valuable battery cell space.
3Ease of manufacture
If conventional modularization process is used to form battery module then manufacturing is improved, but assembly complexity and process time increase
Solution Approach 1:
The battery cells are pre-stacked onto the crossbeams in a standardized sequence and configuration before final pack assembly. This preliminary stacking action simplifies the overall assembly process by pre-organizing components in their final positions, reducing on-site assembly complexity and time while maintaining manufacturing reliability.
Data Source
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AI summary
A battery pack according to an embodiment of the present disclosure comprises: a plurality of battery cell assemblies each including a battery cell stack formed by stacking a plurality of battery cells, and configured to expose at least a portion of both side surfaces and upper and lower surfaces of the battery cell stack; a lower pack frame on which the plurality of battery cell assemblies are mounted; and a crossbeam which is formed in the inside of the lower pack frame and extends along between a pair of adjacent battery cell assemblies among the plurality of battery cell assemblies, wherein the battery cell assembly includes a sub-crossbeam that contacts at least one side surface of the battery cell stack, and wherein the crossbeam and the sub-crossbeam are spaced apart from each other.