Stacked Battery Cell Assembly for Easier Pack Handling
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Solution Overview
Problem
Existing battery pack manufacturing methods, such as the CTP method, face challenges in reducing the weight and volume of battery packs while increasing energy density, due to complex cell mounting structures and risks of battery cell damage during handling and installation.
Innovation Solution
A battery assembly comprising stacked cell units with a support structure that maintains the stacked state and includes a coupling portion for easy transportation, along with cell covers that protect and vent gas from the battery cells, simplifying handling and reducing structural complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the CTP method of mounting multiple battery cells directly into the battery pack case is applied to increase energy density, then energy density is improved, but handling difficulty increases and risk of cell damage occurs
Solution Approach 1:
The invention divides multiple battery cells into a modular stackable unit configuration. Each unit can be independently handled and stacked, transforming the handling of multiple individual cells into the handling of pre-assembled modules. This segmentation resolves the contradiction by maintaining high cell density while improving handling ease through standardized modular units.
Solution Approach 2:
The invention performs preliminary assembly of battery cells into stacked units with integrated support structures before final installation. The support structures and coupling portions are pre-configured to facilitate safe handling and stacking, eliminating the need for complex mounting operations during final assembly. This preliminary action resolves the handling difficulty while maintaining high energy density.
2Volume of stationary object
If battery cells are mounted directly into the battery pack case using CTP method, then volume is reduced, but structural complexity increases due to redundant mounting structures
Solution Approach 1:
The invention merges the support structure, mounting features, and cell containment functions into an integrated stacked unit. The coupling portions are built-in to the unit structure itself rather than being separate mounting components. This merging resolves the contradiction by reducing structural complexity while maintaining compact volume through functional integration.
Solution Approach 2:
The stacked units are designed with universal coupling portions that serve multiple functions: structural support, alignment guidance, and mechanical connection. This multi-functionality eliminates the need for separate mounting structures, reducing overall structural complexity while maintaining the compact volume required for high energy density.
3Manufacturing precision
If multiple battery cells are handled individually during mounting, then manufacturing precision can be maintained, but manufacturing cost increases due to complex installation processes
Solution Approach 1:
The invention segments cells into pre-assembled stacked units with integrated support structures. Each unit maintains precise cell positioning through its internal structure, while the external coupling portions provide standardized interfaces for easy assembly. This segmentation resolves the contradiction by preserving manufacturing precision at the unit level while simplifying the overall manufacturing process.
Solution Approach 2:
The invention performs preliminary precision assembly of cells within stacked units before final installation. The support structures and coupling portions are pre-configured with precise geometries that ensure correct positioning during stacking. This preliminary action resolves the contradiction by maintaining manufacturing precision while reducing the complexity and cost of final assembly operations.
Data Source
AI summary
Disclosed are a battery assembly, and a battery pack and a vehicle including the same. A battery assembly according to an aspect of the present disclosure includes a plurality of stacked cell units each including at least one battery cell, and a support structure configured to support the plurality of cell units and maintain a stacked state of the plurality of cell units, wherein the support structure includes a coupling portion configured to be coupled to a transport structure used to transport the plurality of cell units.