Pouch Cell Battery Pack Assembly Without End Plates
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Solution Overview
Problem
Pouch battery cells face challenges in integration into CTP battery packs due to poor resistance to external impacts and difficult assembly, which affect the efficiency and reliability of the battery system.
Innovation Solution
A battery pack design that includes a casing, a battery cell stack, thermally conductive structural adhesive, and an electrode fixing component with bus bar and bus bar bracket, which allows direct integration of pouch battery cells without end plates, enhancing space utilization and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If pouch battery cells are integrated into CTP battery packs, then volume utilization and energy density are improved, but assembly difficulty increases and resistance to external impacts deteriorates
Solution Approach 1:
The battery pack is segmented into modular units with standardized battery cell modules that can be independently assembled. Each module contains battery cells arranged in a standardized configuration with integrated end plates, allowing for easier handling and assembly while maintaining high volume utilization through compact module design
Solution Approach 2:
Specialized fixing structures and connection components are introduced as intermediaries between the pouch battery cells and the battery pack housing. These intermediaries include reinforced end plates, positioning fixtures, and modular connectors that facilitate easier assembly while providing the necessary mechanical support and impact resistance
2Volume of moving object
If pouch battery cells are integrated into CTP battery packs, then volume utilization and energy density are improved, but resistance to external impacts deteriorates
Solution Approach 1:
Energy-absorbing materials and shock-dampening structures are pre-installed between the pouch battery cells and the battery pack housing. These cushioning elements include foam layers, rubber buffers, and deformable support structures that are positioned in advance to absorb and distribute external impact forces, protecting the battery cells from damage while maintaining compact module design
Solution Approach 2:
The battery pack structure utilizes composite materials combining rigid support elements with flexible protective layers. The end plates and housing incorporate reinforced composites that provide both structural integrity for impact resistance and optimized space utilization, while the layered construction allows for integrated thermal management and electrical insulation
3Volume of moving object
If end plates are eliminated in CTP battery pack design, then volume utilization is improved, but electrical connection reliability may deteriorate
Solution Approach 1:
The electrical connection functions previously performed by end plates are merged into integrated bus bar structures and connection assemblies. These combined structures perform multiple functions including electrical conduction, mechanical support, and positioning, eliminating the need for separate end plates while maintaining reliable electrical connections through direct integration with the battery cell terminals and pack housing
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 solution improves volume utilization and energy density by eliminating the need for end plates, simplifies assembly, and enhances electrical connection reliability.
Implementation Method 1
The thermally conductive structural adhesive is directly bonded between the battery cell stack and the base plate
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Disclosed is a battery pack, including a casing (1), one or more battery cell stacks (3, 4), and an electrode fixing component (100, 200, 300, 400, 500, 600). The battery cell stack (3, 4) is formed by stacking a plurality of pouch battery cells (7) along the thickness direction of the pouch battery cells (7). The electrode fixing component (100, 200, 300, 400, 500, 600) includes bus bars and a bus bar bracket (8) supporting the bus bars. The bus bar bracket (8) is cooperatively connected with a fixing structure on the casing (1), and the bus bars are cooperatively connected with an electrode of the battery cell stack (3, 4).