Pouch Cell Battery Pack Layout for Higher CTP Space Utilization
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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, complicated assembly, and low space utilization, resulting in low energy density.
Innovation Solution
A battery pack design featuring a casing with a battery cell stack, foaming adhesive, side plates, flexible circuit board assembly, battery management system, and connecting assembly, which includes flexible printed circuit boards and flat cables, eliminating the need for traditional brackets and connectors, and utilizing a plastic sheet for positioning and fixing the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pouch battery cells are directly assembled into CTP battery packs, then assembly complexity is reduced, but space utilization rate decreases
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a fixed number of pouch battery cells (e.g., 5 cells per module). This segmentation allows for standardized assembly units that optimize both assembly simplicity and space utilization. The modular structure enables efficient packing arrangements within the battery pack casing.
Solution Approach 2:
Battery modules are nested within the battery pack casing in a structured arrangement. Multiple modules are positioned and fixed together to form the complete battery pack, creating a nested hierarchical structure that maximizes space utilization while maintaining assembly simplicity.
2Device complexity
If pouch battery cells are directly assembled into CTP battery packs, then structural components are eliminated, but energy density decreases
Solution Approach 1:
By segmenting the battery pack into standardized modules, the design eliminates the need for complex individual cell mounting structures while maintaining optimal energy density through efficient module-level structural support and arrangement.
3Strength
If traditional brackets and connectors are used for circuit board assembly, then structural support is provided, but weight and cost increase
Solution Approach 1:
The circuit board is directly integrated with the battery module structure, merging the structural support function with the electrical connection function. This eliminates the need for separate traditional brackets and connectors, reducing both weight and cost while maintaining adequate structural support for the circuit board.
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
Improves space utilization and energy density while simplifying assembly, reducing weight and cost, and enhancing temperature sampling precision.
Implementation Method 1
a foaming adhesive, wherein the foaming adhesive is filled and connected between the tab side of the battery cell stack and the lower housing
Data Source
AI summary
Disclosed is a battery pack that includes: a casing, which includes a lower housing; a battery cell stack, which includes multiple pouch battery cells, and includes two opposite tab sides and side surfaces adjacent to the tab sides, the battery cell stack is disposed in the lower housing; a foaming adhesive, which is filled and connected between the tab side of the battery cell stack and the lower housing; side plates, which are fixed on the side surface of the battery cell stack; a flexible circuit board assembly, which includes: a flexible printed circuit board and an insulating connecting sheet, the flexible printed circuit board is fixedly connected to the battery cell stack through the insulating connecting sheet; a battery management system; a connecting assembly, which is communicatively connected between the battery management system and the flexible printed circuit board, and the connecting assembly is fixedly connected to the side plates.