Pouch Cell Battery Pack Adhesive Structure for CTP Assembly Stability

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Solution Overview

Problem

Pouch cells face difficulties in withstanding external impacts and have poor assembly properties when integrated into CTP type battery packs, leading to poor overall stability and assembly challenges.

Innovation Solution

A battery pack design that includes a casing with adhesive materials, such as thermally conductive structural adhesive and foaming adhesive, to securely hold a stack of pouch battery cells, along with side plates and an upper cap for stability and insulation, and a glue blocking structure to prevent adhesive interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If pouch battery cells are directly integrated into the CTP type battery pack, then the energy density is improved and structural parts are eliminated, but the assembly properties deteriorate and the ability to withstand external impacts worsens

Engineering Contradiction:

Improveenergy densityVSAvoidassembly properties

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent introduces adhesive materials as intermediary substances between the pouch battery cells and the battery pack casing. These adhesives serve as mediators that facilitate the bonding and fixation of pouch cells directly to the casing structure, enabling direct integration while maintaining assembly feasibility and structural integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional mechanical assembly methods (such as rigid fixtures, clamps, or modular holders) with chemical bonding through adhesive materials. This substitution eliminates the need for complex mechanical assembly structures and enables direct integration of pouch cells into the battery pack casing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If pouch battery cells are directly integrated into the CTP type battery pack, then the structural parts are eliminated, but the protection against external impacts deteriorates

Engineering Contradiction:

Improvestructural partsVSAvoidprotection against external impacts

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The adhesive materials serve as intermediary bonding agents that directly connect the pouch battery cells to the battery pack casing, providing mechanical strength and impact resistance without requiring additional structural parts or protective housings

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs adhesive materials that combine multiple functions: structural bonding, impact absorption, and thermal management. These composite adhesive solutions provide both mechanical protection and functional integration, eliminating the need for separate protective structural parts

Inventive Principle:

Principle #40Composite materials

3Volume of moving object

If pouch battery cells are directly integrated into the CTP type battery pack, then the space for battery cells is increased, but the overall stability deteriorates

Engineering Contradiction:

Improvespace for battery cellsVSAvoidoverall stability

Core Design Contradiction:

Volume of moving objectVSStability of the object's composition

Solution Approach 1:

The adhesive materials act as intermediary bonding agents that directly attach the pouch battery cells to the battery pack casing, providing mechanical stability and structural integrity while maximizing the use of available space within the battery pack enclosure

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent merges the functions of structural support, cell fixation, and thermal management into the adhesive material system itself. This integration eliminates the need for separate structural components, thereby maximizing space utilization while maintaining overall stability through the bonded connection between cells and casing

Inventive Principle:

Principle #5Merging (Combining)

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

The design enhances the assembly ease and overall stability of the battery pack, providing effective protection against impacts and ensuring efficient heat dissipation and electrical insulation.

Implementation Method 1

the first adhesive layer is a thermally conductive structural adhesive

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the other adhesive structure is configured as a second adhesive layer and is filled and bonded between an electrode tab side of the battery cell stack and the beam structure... the second adhesive layer is a foaming adhesive

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentEP4576339A1Battery pack and electric vehicle

Publication Date: 2025.06.25 AESC JAPAN LTD

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AI summary

The disclosure relates to the field of batteries, and specifically provides a battery pack (100, 200, 300, 400, 500, 600) and an electric vehicle. The battery pack (100, 200, 300, 400, 500, 600) has a casing (1) including a lower case base plate (13) and a beam structure (14, 15), a cell stack formed by stacking multiple pouch cells in the casing (1), an electrode tabs (231) extending from an end of the pouch battery cell (23) toward the beam structure (14, 15) along a length direction of the pouch battery cells (23), a thermally conductive structural adhesive (25)disposed between the battery cell stack (2) and the lower case base plate (13), and a foaming adhesive (29) filling a space between the electrode tabs (231) and the beam structure (14, 15).