Battery Pack Forced Air Cooling via Bus Bar Flow Paths
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Solution Overview
Problem
Rechargeable battery packs with natural air-cooling structures have low heat radiation performance, making it difficult to handle high-power charging and discharging, while water-cooling solutions are costly due to complex structures and additional devices.
Innovation Solution
A rechargeable battery pack design featuring spacers between cell modules that define flow paths, with bus bars partially setting these paths to allow forced air cooling, effectively removing heat from high-power unit cells while securing the cells against vibration and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If natural air-cooling structure is used, then device complexity is reduced, but heat radiation performance deteriorates
Solution Approach 1:
The cooling system is segmented into multiple flow paths distributed between individual unit cells. Each cell has its own cooling channels formed by spacers and bus bars, allowing heat to be removed locally from each cell rather than using a complex centralized cooling system. This segmentation enables effective heat radiation while keeping the overall structure simple and modular.
Solution Approach 2:
The bus bars serve dual functions: electrical connection between cells and structural components that define cooling flow paths. The spacers simultaneously provide mechanical spacing/support and define cooling channels. This multi-functionality eliminates the need for separate dedicated cooling components, reducing device complexity while maintaining effective heat radiation performance.
2Temperature
If water-cooling solution is used, then heat radiation performance is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses forced air cooling instead of water cooling. Air is circulated through the flow paths defined by spacers and bus bars, creating effective convection currents that remove heat from unit cells. This pneumatic approach avoids the complexity of water cooling systems including pumps, hoses, and leak prevention mechanisms, while still achieving superior heat radiation performance compared to natural air cooling.
Solution Approach 2:
The cooling system utilizes the natural convection properties of air and the thermal characteristics of the battery cells themselves. The flow paths are designed to maximize natural air circulation patterns, and the bus bars and spacers act as heat sinks that passively draw heat from cells. This self-service approach eliminates the need for active pumping systems or complex control mechanisms required by water cooling solutions.
3Temperature
If forced air-cooling method is used, then heat radiation performance is improved, but device complexity increases
Solution Approach 1:
The cooling flow paths are merged with the electrical connection structure. The same bus bars that connect cells electrically also serve as boundaries for cooling channels. Similarly, spacers that provide mechanical support also define the geometry of flow paths. This merging of functions creates an integrated structure where cooling capabilities are built into the existing architecture rather than adding separate cooling components.
Solution Approach 2:
The cooling system utilizes the three-dimensional space between cells, spacers, and bus bars to create effective flow paths. By designing cooling channels that extend along the length of unit cells and utilize vertical and horizontal spaces, the system achieves superior heat radiation performance without requiring additional external cooling components. The flow paths are embedded within the existing structural dimensions.
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 enables efficient heat removal from high-power unit cells, enhancing the battery pack's ability to handle high-power charging and discharging while minimizing costs by using a simpler, effective forced air-cooling method.
Implementation Method 1
heat in a plurality of unit cells charged and discharged with high power is radiated by a forced air-cooling method
Implementation Method 2
flow paths between the unit cells in a length direction of the unit cells, the flow paths being between side surfaces of the spacers and side surfaces of the unit cells
Data Source
Figure 1
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AI summary
A rechargeable battery pack (1) includes a plurality of cell modules (10) connected to each other via bus bars (12), each cell module (10) including a plurality unit cells (11) with electrode terminals connected to the bus bars (12), a plurality of spacers (20) between the cell modules (10), first and second plates (31, 32) coupled to opposite sides of the spacers (20), the first and second plates (31, 32) being configured to support the cell modules (10) therebetween, and flow paths (P) between the unit cells (11) in a length direction of the unit cells (11), the flow paths (P) being between side surfaces of the spacers (20) and side surfaces of the unit cells (11), and being further partially set by sides of the bus bars (12).