Single Cell Frame Assembly for Stable Cylindrical Battery Modules
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Solution Overview
Problem
Conventional battery packs require multiple cell frames, increasing manufacturing costs and complexity, and there is a risk of battery cell movement leading to electrical shorts and reduced durability.
Innovation Solution
A single cell frame design secures cylindrical battery cells without movement, with components for electrical connection and sensing at the central area, improving electrical safety and heat dissipation by positioning cell bottoms near the pack case walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cell frames are used to secure battery cells, then the battery cells are securely held, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges multiple cell frames into a single integrated cell frame structure. The single cell frame includes multiple holding portions that can secure multiple battery cells simultaneously, eliminating the need for separate cell frames for each battery cell or small group. This integration reduces the total number of components while maintaining the security and stability of battery cell fixation.
2Reliability
If multiple cell frames are used to secure battery cells, then the battery cells are securely held, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple cell frames into a single integrated cell frame structure. The single cell frame includes multiple holding portions that can secure multiple battery cells simultaneously, eliminating the need for separate cell frames for each battery cell or small group. This integration reduces the total number of components while maintaining the security and stability of battery cell fixation.
Solution Approach 2:
The single cell frame is designed with multi-functionality to perform multiple roles. It includes multiple holding portions for securing different battery cells, integration portions for connecting with other cell frames or structural components, and support portions for maintaining structural integrity. This multi-functional design allows one component to replace multiple specialized components, reducing overall manufacturing cost.
3Ease of operation
If battery cells are secured in conventional cell frames, then they are held in place, but movement can still occur leading to electrical shorts
Solution Approach 1:
The patent applies local quality by designing specific holding portions with different structural characteristics for different battery cell positions. Each holding portion is specifically configured to match the dimensions and shape of the battery cell it secures, providing localized adaptation. This ensures that each battery cell is firmly held in its designated position with minimal movement risk, while the overall structure maintains electrical safety through proper isolation and positioning.
4Ease of manufacture
If components are distributed throughout the battery pack, then electrical connection is achieved, but heat dissipation efficiency decreases
Solution Approach 1:
The patent reorganizes the spatial arrangement of battery cells and components by transitioning from a distributed two-dimensional layout to a more concentrated three-dimensional arrangement. The single cell frame structure allows for vertical stacking and optimized spatial utilization, positioning battery cells and heat dissipation components in a configuration that enhances thermal management efficiency while maintaining all necessary electrical connections.
Data Source
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AI summary
A cell module assembly according to the present disclosure includes a plurality of cylindrical battery cells, each including a battery can and a top cap coupled to a top portion of the battery can; a cell frame having an accommodation portion and an open portion on one side, wherein the plurality of cylindrical battery cells is received upright in the accommodation portion; and a cell spacer which surrounds all or part of a bottom circumference of the battery can and is coupled to the open portion of the cell frame.