Pouch Battery Module Assembly With Sensing Block and Lateral Cover
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Solution Overview
Problem
The increasing demand for high-capacity and high-output battery packs for electric vehicles complicates the manufacturing process and increases production costs due to the need for multiple battery modules and supporting components, necessitating a simplification of the assembly process to reduce weight and enhance efficiency.
Innovation Solution
A battery pack assembly structure that reduces the number of different parts and simplifies the assembly method by using a pouch-type battery module with a cartridge, sensing block, and lateral cover, along with a fastening system involving protrusions and grooves for snap-fit connections, and a bus bar assembly for electrical connectivity, while incorporating ethylene propylene members for airtight coupling and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the capacity of the battery pack is increased by loading more battery modules or battery cells, then the energy density is improved, but the weight of the vehicle and the cost of production increase
Solution Approach 1:
The end plate and base plate are merged into a single integrated plate structure that simultaneously provides end support and base support functions. This consolidation reduces the number of separate components needed to support the battery cells, thereby reducing overall weight while maintaining structural integrity and support capacity for high-density battery configurations.
Solution Approach 2:
The integrated plate structure serves multiple functions: it acts as both the end plate and base plate, provides structural support, and incorporates the coupling groove mechanism for module assembly. This multi-functionality reduces the total component count and weight while enabling increased battery capacity through more efficient space utilization.
2Quantity of substance
If the capacity of the battery pack is increased by loading more battery modules or battery cells, then the energy density is improved, but the cost of production increases
Solution Approach 1:
The end plate and base plate are merged into a single integrated plate structure that simultaneously provides end support and base support functions. This consolidation reduces the number of separate components needed to support the battery cells, thereby reducing overall weight while maintaining structural integrity and support capacity for high-density battery configurations.
Solution Approach 2:
The integrated plate structure serves multiple functions: it acts as both the end plate and base plate, provides structural support, and incorporates the coupling groove mechanism for module assembly. This multi-functionality reduces the total component count and weight while enabling increased battery capacity through more efficient space utilization.
3Quantity of substance
If the number of battery modules is increased to improve capacity, then the energy density is improved, but the manufacturing process becomes complicated
Solution Approach 1:
The battery pack is divided into modular battery modules that can be independently manufactured and then assembled. Each module contains battery cells arranged in a standardized configuration with integrated support structures, allowing for simplified individual module production and efficient scaling to achieve desired capacity without proportionally increasing overall manufacturing complexity.
Solution Approach 2:
The end plate and base plate are merged into a single integrated plate structure that simultaneously provides end support and base support functions. This consolidation reduces the number of separate components needed to support the battery cells, thereby reducing overall weight while maintaining structural integrity and support capacity for high-density battery configurations.
Data Source
AI summary
An embodiment battery module includes a plurality of battery cells provided as a pouch type, a plurality of cartridges, each of the cartridges holding the battery cells that are adjacent to each other and form a pair, a sensing block coupled to a lateral side of the plurality of cartridges to bind the plurality of cartridges to each other, the sensing block including a first connector configured to electrically connect the plurality of battery cells and a second connector configured to measure voltage of the plurality of battery cells, and a lateral cover coupled to an outward side of the sensing block to bind the sensing block and the plurality of cartridges to each other, the lateral cover including a first opening that exposes the first connector to an outside and a second opening that exposes the second connector to the outside.