Battery Pack Cell Case with Integrated Cooling Passages
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Solution Overview
Problem
Conventional battery packs require complex structures and increased volume due to the need for separators and middle frames to maintain cooling passages and structural integrity, leading to reduced assembly efficiency and increased production costs.
Innovation Solution
A battery pack design that allows direct stacking of cell assemblies with integrated cooling passages defined by windows and recesses in the cell case, eliminating the need for separators and middle frames, and using a fixing window member made of compressible material to maintain structural integrity without increasing volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separators and middle frames are used to maintain cooling passages and structural integrity, then structural strength and cooling function are improved, but device complexity and volume increase
Solution Approach 1:
The patent combines the cooling passage formation and structural support functions into the cell case itself. The cell case includes integrated recesses that form cooling passages when cell assemblies are stacked, eliminating the need for separate separators and middle frames. This merging of functions reduces device complexity while maintaining structural integrity and cooling efficiency.
2Temperature
If separators are used to space cell cartridges, then cooling passages are defined, but volume and number of parts increase
Solution Approach 1:
The cooling passage definition function is merged into the cell case structure through integrated recesses. When cell assemblies are stacked, these recesses automatically form cooling passages without requiring separate separator components. This eliminates the need for additional parts while maintaining effective cooling channels, thereby reducing battery pack volume.
3Strength
If middle frames are used to reinforce positions between unit cells, then structural strength is improved, but volume and production cost increase
Solution Approach 1:
The structural reinforcement function previously requiring separate middle frames is merged into the cell case design. The cell case includes integrated recesses and structural features that provide necessary support between unit cells without requiring additional middle frame components. This reduces cell cartridge volume and simplifies the overall structure while maintaining structural strength.
4Strength
If multiple assembly processes are used to fabricate cell cartridges into unit modules, then structural integrity is maintained, but productivity and assembly efficiency decrease
Solution Approach 1:
The patent segments the battery pack into directly stackable cell assemblies, each containing unit cells within an integrated cell case. This segmentation allows cell assemblies to be independently manufactured and then directly stacked to form the final battery pack structure, eliminating the intermediate step of fabricating cell cartridges into unit modules. This reduces the number of assembly processes while maintaining structural integrity through the integrated cell case design.
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
This design simplifies the production process, reduces the number of parts and volume, enhances cooling efficiency, and achieves higher energy density by eliminating the need for separators and middle frames, while maintaining structural integrity.
Implementation Method 1
a fixing window member fixing the unit cells to inner surfaces of the first and second cases under pressure
Implementation Method 2
a fixing window member made of compressible material to maintain structural integrity
Data Source
AI summary
The present invention features a battery pack, that is provided to supply electricity to a variety of electric parts, such as a drive motor, installed in an environment friendly electric vehicle such as a fuel cell vehicle or a hybrid electric vehicle. Preferably, the battery pack is configured to stack cell assemblies. Each cell assembly includes a cell case. The cell case includes windows in opposite surfaces thereof such that unit cells are exposed, and recesses in opposite long lateral faces thereof such that the windows communicate with an outside. The windows and the recesses define cooling passages between the stacked cell assemblies.