Battery Pack Heat Sink Integration for Compact Cell Support and Cooling
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Solution Overview
Problem
Conventional battery packs face challenges with increased fabrication costs, complex assembly processes, reduced energy density, and larger size due to the use of multiple plate structures in the cell frame, which also affect price competitiveness and cooling efficiency.
Innovation Solution
A battery pack design incorporating a busbar assembly connected to battery cells, a heat sink with a thermally conductive member, and a cooling system with a heat sink and cooling channels, along with a thermally conductive member filled between the busbar assembly and battery cells, enhancing electrical connections and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the strength and stability of the battery pack is improved, but the fabrication cost increases and the assembly process becomes complex
Solution Approach 1:
The patent combines the cell frame structure with the heat sink into a single integrated component. The heat sink serves dual functions as both a cooling device and as the structural frame that accommodates battery cells, eliminating the need for separate plate assemblies and reducing overall complexity while maintaining structural strength
Solution Approach 2:
The heat sink is designed to perform multiple functions simultaneously: it provides thermal management through cooling channels, serves as the structural frame (cell frame) for mounting battery cells, and provides mechanical support. This multi-functionality reduces the number of components needed and simplifies the assembly process
2Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the strength and stability of the battery pack is improved, but the total size increases and energy density decreases
Solution Approach 1:
By merging the cell frame and heat sink into one integrated component, the patent eliminates redundant structural elements and reduces the total volume occupied by framing structures. This allows more space for active battery materials, thereby improving energy density while maintaining necessary structural strength
Solution Approach 2:
The integrated heat sink uses thin-walled structures and optimized channel designs that provide sufficient structural strength with minimal material thickness. This reduces the volume consumed by structural components and maximizes the space available for energy-storing battery materials
3Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the strength and stability of the battery pack is improved, but the fabrication cost increases
Solution Approach 1:
The integration of the cell frame and heat sink into a single component reduces the total number of parts that need to be manufactured, procured, and assembled. This simplification directly reduces fabrication costs while the integrated design maintains structural strength through optimized thermal management channels that also serve as structural elements
Solution Approach 2:
The patent employs optimized channel configurations and structural parameters in the integrated heat sink that provide maximum strength-to-weight ratio and structural efficiency. By carefully selecting and optimizing geometric parameters, the design achieves necessary structural strength with minimal material usage, thereby reducing manufacturing costs
4Temperature
If cooling channels are added to the heat sink, then the cooling performance is improved, but the device complexity and fabrication cost increase
Solution Approach 1:
The cooling channels are integrated directly into the heat sink structure itself rather than being separate components. This merging of cooling functionality into the structural element provides effective thermal management without adding additional complexity or separate parts to the system
Solution Approach 2:
The heat sink structure serves dual purposes: as the structural frame for mounting battery cells and as the cooling system with integrated channels. This multi-functionality allows cooling performance improvement without increasing overall device complexity, as the same component performs both structural and thermal management functions
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 energy density, strength, price competitiveness, and cooling performance while simplifying the assembly process, resulting in a more efficient and compact battery pack.
Implementation Method 1
a thermally conductive member filled in a space between the plurality of battery cells on the heat sink
Implementation Method 2
a heat sink which is spaced a predetermined distance apart from the busbar assembly and supports a bottom of plurality of battery cells
Implementation Method 3
a cooling channel in which a cooling water flows
Data Source
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AI summary
A battery pack according to an embodiment of the present disclosure includes a battery cell assembly including a plurality of battery cells; a busbar assembly provided on the battery cell assembly; a heat sink which is spaced a predetermined distance apart from the busbar assembly and supports a bottom of plurality of battery cells; and a thermally conductive member filled in a space between the plurality of battery cells on the heat sink.