Battery Pack Bus Bar Layout for Cooling and Output Routing
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Solution Overview
Problem
Existing battery packs face challenges in achieving efficient electrical output, space utilization, and robustness against vibrations and shocks, particularly when used in high-power applications like electric vehicles, due to issues with electrical path length, interference between cooling structures and electrical connections, and physical interference between battery cells.
Innovation Solution
A battery pack design with non-adjacent electrical connections using first and second bus bars on side surfaces and a third bus bar on the rear side, along with cooling plates on long and short sides, to minimize electrical and physical interference, enhance cooling area, and facilitate easy electrical connection to external devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If output terminals are formed at adjacent positions to each other, then electrical connection to a set device is easily achieved, but physical and electrical interference between cooling structure and electrical connection may occur
Solution Approach 1:
The patent positions output terminals at adjacent locations on the same side surface of the battery pack, utilizing two-dimensional spatial arrangement to achieve both ease of electrical connection and separation from cooling structures that may be positioned on opposite sides or different planes, thereby eliminating physical and electrical interference while maintaining operational convenience
2Temperature
If cooling plates are disposed on upper and lower surfaces of battery cells, then cooling area is increased, but device complexity increases
Solution Approach 1:
The cooling plates are designed to serve multiple functions: they provide thermal management by cooling battery cells, act as structural support elements for the battery pack assembly, and facilitate electrical isolation between adjacent cells. This multi-functionality increases cooling area while minimizing additional structural complexity
3Object-affected harmful factors
If bus bars are arranged on long side and short side of battery cell, then physical and electrical interference is eliminated, but electrical path length increases
Solution Approach 1:
The electrical connection system is segmented into multiple bus bars positioned at different locations (long side and short side) that collectively provide complete electrical connectivity. This segmentation allows current to flow through multiple shorter paths rather than one long path, reducing overall electrical resistance and interference while maintaining efficient current distribution across all battery cells
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 improves electrical output, space utilization, and robustness against external shocks and vibrations, while ensuring efficient cooling and easy connection to external devices, making it suitable for high-power applications.
Implementation Method 1
first and second cooling plates respectively disposed on first and second side surfaces of the battery module
Implementation Method 2
first and second bus bars electrically connecting the plurality of battery cells to each other
Data Source
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AI summary
A battery pack is disclosed. The battery pack includes a plurality of battery cells arranged back and forth in a first direction, each including a pair of main surfaces arranged to face each other in the first direction, connecting the pair of main surfaces to each other, and including upper and lower surfaces forming a pair of long sides facing each other, and first and second side surfaces forming a pair of short sides facing each other, first and second bus bars electrically connecting the plurality of battery cells to each other, and electrically connecting the battery cells alternately arranged so as not to be adjacent to each other in the first direction on the first and second side surfaces, respectively, and a third bus bar that electrically connects first and second output terminals formed together on a front side of the plurality of battery cells in the first direction and adjacent battery cells to each other by detouring a rear side of the plurality of the battery cells. According to the present disclosure, provided is an advantageous battery pack which may be easily electrically connected to a set device, has a simplified structured with improved electrical output, may eliminate interference between a cooling structure and an electrical connection structure, and is favorable for slimming.