Logical Pouch Cell Layout With Reinforced Case for Dense Battery Packs

The patent transitions from a lattice arrangement (three-dimensional grid structure) to a linear longitudinal arrangement of cells within a case. This dimensional reorganization allows cells to be stacked end-to-end along the length of the case rather than requiring spacing in multiple directions, thereby maximizing space utilization while maintaining structural integrity through the case enclosure.

The patent integrates multiple functions into fewer components. The busbar is designed to serve both as an electrical connector and as a structural element for mounting. The case itself provides both mechanical protection and structural support, reducing the need for additional isolation covers and reinforcement plates. This merging of functions reduces the total volume occupied by connection and support components.

The patent applies safety measures locally rather than uniformly throughout the pack. Thermal management and safety components are concentrated at critical locations such as the ends of the cell assembly rather than between each cell. This localized approach provides necessary safety protection while minimizing the volume consumed by safety components, thereby preserving energy density.