Battery Pack Bus Bar and Cooling Unit Integration
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Solution Overview
Problem
Conventional battery packs face challenges in terms of cost competitiveness, manufacturing efficiency, energy density, and cooling performance due to their complex frame structure made of multiple plates, which increases size and manufacturing costs.
Innovation Solution
A battery pack design featuring a bus bar assembly, cooling unit, and side structure unit that includes a cooling tube with alternating convex and concave portions, a filling member made of potting resin, and a side structure unit that secures the cooling unit and battery cells, enhancing rigidity and cooling efficiency while simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cell frame structure configured as an assembly of multiple plates is used, then rigidity is secured, but manufacturing cost increases and assembly process becomes complicated
Solution Approach 1:
The patent combines the cell frame structure with the cooling unit into a single integrated component. The side plates serve dual functions as both structural support elements and cooling fluid passages, eliminating the need for separate cooling units and reducing assembly complexity while maintaining rigidity
Solution Approach 2:
The side plates are designed to perform multiple functions simultaneously: providing structural rigidity as frame components and serving as cooling channels for thermal management. This multi-functionality reduces the total number of components and simplifies the overall assembly process
2Strength
If a conventional cell frame structure configured as an assembly of multiple plates is used, then rigidity is secured, but manufacturing cost increases
Solution Approach 1:
The cell frame and cooling unit are merged into a single integrated structure where side plates serve both structural and thermal management functions, reducing part count and manufacturing cost while maintaining necessary rigidity
Solution Approach 2:
The design changes the functional parameters of the side plates from purely structural to dual-purpose (structural + cooling), allowing a single component to replace multiple components and reduce overall manufacturing complexity and cost
3Strength
If a conventional cell frame structure configured as an assembly of multiple plates is used, then structural support is provided, but the size of the entire battery pack is increased
Solution Approach 1:
The cooling unit is merged with the cell frame structure, allowing cooling passages to be formed within the side plates themselves. This integration eliminates additional space that would be required for separate cooling units, reducing overall battery pack volume while maintaining structural support
4Stability of the object's composition
If multiple plates are assembled to form a cell frame, then rigidity is achieved, but the assembly process becomes complicated
Solution Approach 1:
The cell frame and cooling unit are combined into a single integrated component structure, reducing the number of assembly steps from assembling multiple separate plates and cooling units to assembling a unified structure, thereby improving productivity
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 achieves improved rigidity, increased energy density, enhanced cooling performance, and reduced manufacturing complexity and costs, making it more competitive.
Implementation Method 1
a cooling unit disposed at the second side of the bus bar assembly and arranged between the plurality of battery cells along a longitudinal direction of the battery pack
Implementation Method 2
a cooling channel provided in the cooling tube and configured to circulate a cooling fluid for cooling the plurality of battery cells
Data Source
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AI summary
Disclosed is a battery pack including a plurality of battery cells; a bus bar assembly having a first side and a second side, the second side of the bus bar assembly provided to a first side of the plurality of battery cells and electrically connected to the plurality of battery cells; a cooling unit disposed at the second side of the bus bar assembly and arranged between the plurality of battery cells along a longitudinal direction of the battery pack; and a side structure unit configured to accommodate the cooling unit and the plurality of battery cells, wherein opposite ends of the cooling unit are fixed to the side structure unit.