Cylindrical Battery Pack Layout to Prevent Condensation Short Circuits
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Solution Overview
Problem
The risk of short circuits in battery packs due to condensation forming on heat exchange plates and flowing to bus members, leading to metal fatigue and poor structural stability, is exacerbated by the need for insulating materials that compromise strength.
Innovation Solution
The bus member and heat exchange plate are positioned on different sides of the cylindrical batteries, with a limit plate on the peripheral wall, preventing condensation flow and reducing metal fatigue, while ensuring structural stability through separate side arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the bus member and heat exchange plate are disposed on the same side of the battery, then the structure is more compact, but condensation flows to the bus member causing short circuit and metal fatigue
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement where bus members and heat exchange plates share the same side to a three-dimensional spatial arrangement where they are positioned on opposite sides of the battery. This dimensional separation prevents condensation flow paths from reaching the bus member while maintaining overall pack compactness through optimized vertical and horizontal spacing.
2Reliability
If the limit plate is made of insulating material to prevent short circuit, then the short circuit risk is reduced, but the strength and structural stability decrease
Solution Approach 1:
The patent introduces a dielectric layer as an intermediary substance between the conductive limit plate and the bus member. This allows the limit plate to be made of high-strength metal material while the dielectric layer provides the necessary insulation, thus resolving the contradiction between strength and insulation requirements.
3Temperature
If the bus member is exposed to repeated temperature differences from the heat exchange plate, then heat exchange efficiency is improved, but metal fatigue increases reducing reliability
Solution Approach 1:
The patent extracts the bus member from the thermal environment by positioning it on the opposite side of the battery from the heat exchange plate. This separation removes the bus member from the path of repeated temperature cycles while the battery itself continues to undergo thermal management, thus improving reliability without compromising heat exchange efficiency.
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 configuration reduces the risk of short circuits, enhances structural stability, and improves the reliability and strength of the battery pack by avoiding interference and the need for insulating materials.
Implementation Method 1
a heat exchange plate configured for exchanging heat with the battery
Implementation Method 2
exchanging heat with the battery
Implementation Method 3
condensation is generated when the heat exchange plate cools the battery
Implementation Method 4
the condensation may cause a short circuit of the battery pack after the condensation flows to the heat exchange plate
Data Source
Figure 1~2
Figure 3~4
AI summary
A battery pack is provided, the battery pack including a box (10), at least one battery row (20), a heat exchange plate (30), a bus member (40) and a limit plate (50); the axis of a plurality of cylindrical batteries (21) of the battery row (20) is parallel to the bottom of the battery box (10); the bus member (40) is configured for electrically connecting the plurality of cylindrical batteries (21); the limit plate (50) is configured for limiting the battery; wherein a peripheral wall (203) located between a first end wall (201) of the cylindrical battery (21) and a second end wall (202) of the cylindrical battery (21); the heat exchange plate (30) is disposed opposite to the first end wall (201); the bus member (40) is disposed opposite to the second end wall (202); and the limit plate (50) is disposed opposite to the peripheral wall (203).