Battery Pack Bus Bar and Side Structure for Rigidity
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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 cell frame structure, which increases manufacturing costs and size while compromising on rigidity and cooling efficiency.
Innovation Solution
A battery pack design featuring a bus bar assembly with a single-layered sub bus bar and a side structure unit that accommodates cooling units and battery cells, using an insulating bus bar cover and a zigzag bus bar bridge for efficient electrical connections and improved cooling, along with a modular unit structure that enhances rigidity and reduces material usage.
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 multiple separate plate components (front plate, rear plate, side plates, lower plate, upper plate) into a single integrated cell frame structure. This merging reduces the number of parts from 5+ separate plates to one unified structure, simplifying the assembly process while maintaining the necessary rigidity through the integrated design that preserves structural support functions.
Solution Approach 2:
The integrated cell frame is designed to perform multiple functions simultaneously: providing structural rigidity, accommodating battery cells, supporting cooling units, and enabling electrical connections. This multi-functionality eliminates the need for separate dedicated components for each function, reducing overall assembly complexity while maintaining performance.
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:
By merging multiple plate components into a single integrated cell frame, the patent reduces manufacturing complexity and material waste associated with producing and assembling multiple separate parts. This consolidation lowers tooling costs, reduces inventory requirements, and simplifies quality control, thereby reducing overall manufacturing cost while maintaining rigidity through the integrated structural design.
3Strength
If a 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 increases
Solution Approach 1:
The integrated cell frame eliminates gaps and overlap regions inherent in multi-plate assemblies, creating a more compact structure. By combining front, rear, side, lower, and upper plates into one unified component, the patent reduces the overall envelope volume required for structural support, thereby decreasing battery pack size while maintaining necessary structural integrity.
4Power
If multiple battery cells are connected in series or parallel, then output voltage and charge/discharge capacity are increased, but the number of components and assembly complexity increase
Solution Approach 1:
The integrated cell frame is designed to accommodate multiple battery cells configured in series or parallel arrangements while providing unified structural support and integrated cooling. This multi-functional design handles both electrical configuration requirements and structural requirements through a single component system, reducing the number of separate structural components needed as cell numbers increase.
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 cost competitiveness by simplifying the assembly process and reducing material requirements, while maintaining effective electrical connections and thermal management.
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 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 3
the bus bar electrode assembly including a single-layered sub bus bar having a positive electrode connection portion and a negative electrode connection portion
Data Source
AI summary
Discussed 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, the bus bar electrode assembly including a single-layered sub bus bar having a positive electrode connection portion and a negative electrode connection portion; 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.