Pouch Cell Battery Pack Structure Without Module Cases
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Solution Overview
Problem
Existing battery packs face issues of increased weight and volume, decreased energy density, and complex assembly processes due to the use of box-shaped metal cases for battery modules, which hinder efficient handling and mounting of battery cells.
Innovation Solution
A battery pack design that accommodates pouch-type battery cells directly in a pack case, utilizing a heat sink and cell cover structure with support ribs or concave portions to enhance space efficiency, thermal conductivity, and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are accommodated in box-shaped metal cases to form battery modules, then the battery cells are protected and structured, but the weight and volume of the battery pack increases
Solution Approach 1:
The invention extracts and removes the box-shaped metal case from the battery module structure. Instead of enclosing battery cells in separate metal cases to form modules, the cells are directly accommodated in the pack case, eliminating the redundant metal casing and reducing overall weight while maintaining protection through alternative means.
Solution Approach 2:
The invention merges the battery module case with the pack case into a single integrated structure. By directly accommodating battery cells in the pack case without intermediate metal cases, the design combines multiple protective functions into one unified structure, reducing weight and simplifying the overall architecture.
2Reliability
If battery cells are accommodated in box-shaped metal cases to form battery modules, then the battery cells are protected and structured, but the volume of the battery pack increases
Solution Approach 1:
The invention extracts and removes the box-shaped metal case from the battery module structure. Instead of enclosing battery cells in separate metal cases to form modules, the cells are directly accommodated in the pack case, eliminating the redundant metal casing and reducing overall volume while maintaining protection through alternative means.
Solution Approach 2:
The invention merges the battery module case with the pack case into a single integrated structure. By directly accommodating battery cells in the pack case without intermediate metal cases, the design combines multiple protective functions into one unified structure, reducing volume and simplifying the overall architecture.
3Power
If multiple battery modules are connected to form a battery pack, then the required voltage and capacity are achieved, but the energy density of the battery pack decreases
Solution Approach 1:
The invention extracts and eliminates the intermediate battery module structure, allowing battery cells to be directly connected and arranged in the pack case. This removes the volumetric overhead of separate module cases, enabling more efficient space utilization and higher energy density while achieving the required voltage and capacity through direct cell configurations.
4Reliability
If battery cells are mounted using complex assembly processes, then the battery cells are securely fixed, but the manufacturing cost increases and assembly is time-consuming
Solution Approach 1:
The invention segments the pack case into multiple trays that can be independently assembled and then combined. Each tray can hold and secure battery cells individually, allowing for simplified assembly where cells are mounted on trays first and then the trays are integrated into the pack case, reducing overall assembly complexity and time.
Solution Approach 2:
The invention implements preliminary action by pre-assembling battery cells on trays before integrating them into the final pack structure. This allows battery cells to be securely fixed on individual trays in a controlled manner, and then the pre-assembled trays are easily integrated into the pack case, simplifying the overall manufacturing process.
5Reliability
If heavy metal cases are used for battery modules, then the battery cells are protected, but the handling and mounting of battery cells becomes difficult
Solution Approach 1:
The invention extracts and removes the heavy box-shaped metal cases from the battery module structure. By eliminating these heavy enclosures and directly accommodating battery cells in the pack case or on trays, the design significantly reduces weight, making handling and mounting operations much easier while maintaining protection through alternative design features.
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 reduces overall weight and volume, increases energy density, simplifies assembly, and improves coupling and thermal conductivity while preventing damage to battery cells.
Implementation Method 1
a pack case accommodating the plurality of pouch-type battery cells in an internal space and provided with a heat sink
Data Source
AI summary
Disclosed are a battery pack and a vehicle including the same. A battery pack according to an embodiment of the present disclosure includes a plurality of pouch-type battery cells; a pack case accommodating the plurality of pouch-type battery cells in an internal space and provided with a heat sink; and a cell cover that at least partially surrounds and supports at least some of the pouch-type battery cells among the plurality of pouch-type battery cells in the internal space of the pack case, wherein the heat sink is configured in a structure for pressing the cell cover.