Pouch Battery Cell Layout for Higher Module Space Utilization
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Solution Overview
Problem
Conventional battery modules have low space utilization due to dead spaces between electrode lead parts and complex parts and processes, including separate sensing components and additional structural elements.
Innovation Solution
A battery cell with a unidirectional pouch structure featuring protrusions on the battery case to accommodate electrode leads, integrated busbar frames, and a simplified module design with a heat conductive resin layer for improved cooling, reducing the need for separate components and enhancing space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional bidirectional pouch battery cell is used with electrode lead parts on both sides, then electrical connection is achieved, but dead spaces are formed between electrode lead parts reducing space utilization
Solution Approach 1:
The patent applies asymmetry by transitioning from a bidirectional battery cell structure to a unidirectional structure. The electrode assembly and electrode leads are positioned asymmetrically within the pouch, with all electrode leads concentrated on one side of the battery case. This asymmetric arrangement eliminates the dead spaces that formed between opposing electrode lead parts in the conventional symmetric bidirectional design, thereby improving space utilization rate in the battery module.
Solution Approach 2:
The patent repositions the electrode leads from a bidirectional arrangement (both sides of the battery) to a unidirectional arrangement (one side only). This dimensional reorganization concentrates all electrical connection points in a single direction, eliminating the need for space on both sides and removing the dead spaces that previously reduced overall module space utilization.
2Ease of manufacture
If electrode lead parts are formed on side parts of the battery cell, then electrical connection is achieved, but the width extension of electrode lead is very limited
Solution Approach 1:
The patent moves the electrode leads from the side surfaces of the battery cell to the end surfaces. By positioning the electrode leads on the end surfaces rather than the side surfaces, the patent充分利用 the available area at the ends of the battery case, allowing for greater width extension of the electrode leads without being constrained by the limited side part area.
3Reliability
If separate sensing components and additional structural elements are used, then voltage sensing and temperature sensing are achieved, but parts and processes become complicated
Solution Approach 1:
The patent integrates the sensing functions into the existing electrode lead structure. The same electrode leads that provide electrical connection also serve as the pathways for voltage sensing and temperature sensing. This merging of functions eliminates the need for separate sensing components and additional structural elements, thereby reducing parts and manufacturing processes while maintaining reliable sensing capabilities.
Solution Approach 2:
The electrode leads are designed to serve multiple functions simultaneously: electrical connection, voltage sensing, and temperature sensing. This multi-functionality approach allows a single component structure to fulfill multiple roles, eliminating the need for separate dedicated sensing components and simplifying the overall battery cell design.
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 simplifies parts and processes while increasing space utilization and cooling efficiency, allowing for a more compact and efficient battery module with improved energy density and reduced internal resistance.
Implementation Method 1
a heat conductive resin layer for improved cooling
Data Source
AI summary
A battery cell, a battery module, and a battery pack including the same are provided. The battery cell includes a battery case accommodating an electrode assembly and having outer periphery sealed by heat fusion, an electrode lead electrically connected to an electrode tab of the electrode assembly and protruding outward of the battery case, and a first protrusion and a second protrusion protruding in a direction to which the electrode lead protrudes formed on one side surface of the battery case, the electrode lead being located between the first protrusion and the second protrusion. Parts and processes are simplified for the battery cell and the battery module including the same, while increasing space utilization rate of the battery module.