Bent Cover Frame Battery Pack for Dense Cell Cooling
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Solution Overview
Problem
Conventional battery packs face challenges in reducing manufacture cost, improving heat dissipation efficiency, and enhancing product stability due to limitations in accommodating a larger number of cylindrical battery cells, which results in lower energy density and increased costs from heavy fixing members and exterior cases.
Innovation Solution
A battery pack design featuring a cover structure with bent cover frames that accommodate battery modules without the need for internal welding spaces, allowing for closer packing of cells, improved heat dissipation through conductive members, and reduced manufacturing complexity with a simpler assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional battery pack uses metal plates for electrical connection and welding, then electrical connectivity is achieved, but welding space is required inside module housing which creates dead space and lowers energy density
Solution Approach 1:
The patent extracts the welding operation from the internal module housing space and relocates it to the external battery pack housing. The metal plates extend outward from the module housing to the battery pack housing, allowing welding to occur outside the module housing. This eliminates the dead space requirement inside the module housing and increases the number of battery cells that can be accommodated.
Solution Approach 2:
The patent transitions the welding operation from a two-dimensional internal space constraint to a three-dimensional external arrangement. By extending metal plates outward and performing welding in the external battery pack housing, the solution utilizes additional spatial dimensions to resolve the space conflict, thereby increasing energy density without compromising electrical connectivity.
2Stability of the object's composition
If fixing members such as bushings or metal rods are used to protect and fix battery modules, then mechanical stability is improved, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent merges the fixing function with the existing battery pack housing structure. The housing is designed to directly receive and secure the battery modules without requiring separate fixing members. This integration eliminates the need for additional bushings, metal rods, or other fixing components, thereby reducing manufacturing cost and time while maintaining mechanical stability.
Solution Approach 2:
The battery pack housing serves multiple functions: it provides mechanical protection, structural support, and direct fixation for the battery modules. By designing the housing to perform these multiple functions simultaneously, the patent eliminates the need for separate dedicated fixing members, reducing both component count and manufacturing complexity.
3Strength
If a large and heavy outer case is provided to ensure mechanical rigidity, then structural strength is improved, but energy density deteriorates due to increased weight and size
Solution Approach 1:
The patent optimizes the housing parameters by using thinner wall sections and lighter materials while maintaining structural integrity through intelligent structural design. The housing incorporates ribs, partitions, and optimized thickness variations that provide necessary mechanical rigidity with minimal material usage, thereby reducing overall weight and improving energy density.
Solution Approach 2:
The housing is designed with non-uniform thickness and localized reinforcement only where structurally necessary. Critical areas receive enhanced support through strategic rib placement and thickness variation, while non-critical areas use minimal material. This localized quality approach ensures mechanical rigidity where needed while minimizing overall weight and maximizing energy density.
4Quantity of substance
If battery modules are closely arranged to accommodate more cells in limited space, then energy density is improved, but heat dissipation becomes more challenging
Solution Approach 1:
The patent introduces thermal conductive members as intermediaries between the battery modules and the housing. These members facilitate heat transfer from the closely arranged battery cells to the housing, which acts as a heat sink. This intermediary thermal path enables effective heat dissipation even when battery modules are densely packed, resolving the conflict between energy density and thermal management.
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 reduces manufacturing costs, enhances energy density by allowing more cells in a smaller space, improves heat dissipation efficiency, and increases product stability through effective protection and cooling mechanisms.
Implementation Method 1
improved heat dissipation efficiency through conductive members
Data Source
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AI summary
Disclosed is a battery pack having a reduced manufacture cost, improved heat dissipation efficiency and enhanced product stability. The battery pack includes a cover structure including a first cover frame having a plate shape with both front and rear ends bent leftward to form an inner space and a second cover frame having a portion coupled to the first cover frame and having a plate shape with both front and rear ends bent rightward to form an inner space; a first battery module having a plurality of battery cells; and a second battery module having a plurality of battery cells.