Battery Pack Cooling Unit Integrated With Busbar Assembly
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Solution Overview
Problem
Conventional battery packs face challenges with high manufacturing costs, complex assembly processes, and poor cooling performance due to the structural characteristics of their cell frames, which complicate the arrangement of cooling units.
Innovation Solution
A battery pack design featuring a busbar assembly connected to a cooling unit that includes a cooling tube with a cooling channel, a fixing holder, and a filler member, allowing for improved cooling performance and manufacturing efficiency by enhancing contact area and stability of electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cell frame including an assembly of plates is used, then the battery pack can accommodate battery cells and ensure strength, but the manufacturing cost is high and the assembly process is complex
Solution Approach 1:
The cooling unit is integrated with the cell frame structure, merging two separate components (cooling system and structural frame) into a unified design. The cooling unit includes a cooling plate that serves both as a structural component and as a heat dissipation element, eliminating the need for separate cooling plates and reducing assembly complexity
Solution Approach 2:
The cooling unit is designed to perform multiple functions: it provides structural support as part of the cell frame, serves as a cooling surface for heat dissipation, and provides mounting positions for battery modules. This multi-functionality reduces the overall number of components needed in the battery pack
2Temperature
If a conventional cell frame including an assembly of plates is used, then the battery pack can accommodate battery cells, but the cooling units cannot be properly arranged resulting in low cooling performance
Solution Approach 1:
The cooling unit is merged with the cell frame structure, allowing the cooling channels to be directly integrated into the structural framework. This integration enables proper arrangement of cooling units along the battery module stacking direction while maintaining structural integrity
Solution Approach 2:
The cooling channels are arranged in a three-dimensional configuration within the cooling unit, with channels extending in multiple directions to optimize heat dissipation from different surfaces of the battery modules. This spatial arrangement improves cooling efficiency without increasing external complexity
3Power
If multiple battery cells are connected in series/parallel to form battery modules, then the required output voltage and charge/discharge capacity are achieved, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The battery pack is divided into multiple standardized battery modules, each containing a specific number of battery cells connected in series/parallel. This segmentation allows for modular assembly, where identical modules can be manufactured independently and then stacked to achieve the required total capacity and voltage, significantly improving manufacturing efficiency
Solution Approach 2:
The cell frame design serves multiple purposes: it provides structural support, facilitates modular assembly of battery cells into modules, and integrates the cooling system. This multi-functionality reduces the number of separate manufacturing processes needed and simplifies the overall assembly procedure
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 cooling performance and manufacturing efficiency, with increased energy density and stability of electrical connections, while reducing manufacturing costs.
Implementation Method 1
a cooling channel provided in the cooling tube and configured to circulate a cooling fluid for cooling the battery cells
Data Source
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AI summary
A battery pack according to an embodiment of the present disclosure includes a plurality of battery cells, a busbar assembly disposed on one side of the plurality of battery cells and electrically connected to the plurality of battery cells, and a cooling unit disposed between the plurality of battery cells and secured to the busbar assembly.