Battery Pack Cooling Structure for Higher Energy Density
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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 plates in the cell frame structure, leading to compromised price competitiveness and cooling performance.
Innovation Solution
A battery pack design incorporating a battery cell assembly with a busbar assembly, a cooling unit positioned below the busbar assembly, and a thermally conductive member filled between the cooling unit and battery cells, featuring a cooling tube with alternating convex and concave portions for enhanced cooling performance.
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 battery pack ensures strength, but the fabrication cost increases and the assembly process becomes complex
Solution Approach 1:
The patent merges the cell frame structure into a single integrated case body that accommodates battery cells directly, eliminating the need for separate front plate, rear plate, side plate, lower plate, and upper plate assemblies. This consolidation maintains structural strength while dramatically simplifying the assembly process and reducing fabrication cost.
Solution Approach 2:
The case body serves multiple functions simultaneously: it provides structural strength, acts as a container for battery cells, and eliminates the need for separate frame components. This multi-functional design resolves the contradiction by achieving strength requirements without complex multi-component assembly.
2Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the battery pack ensures strength, but the total size increases and energy density decreases
Solution Approach 1:
By consolidating multiple frame plates into a single case body structure, the patent eliminates redundant structural components and reduces the overall volume occupied by the frame assembly, thereby decreasing battery pack size while maintaining necessary strength.
Solution Approach 2:
The patent extracts and removes unnecessary intermediate frame components (front plate, rear plate, side plate, lower plate, upper plate) from the design, keeping only the essential case body structure. This extraction reduces total volume and improves energy density while preserving structural integrity.
3Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the battery pack ensures strength, but the fabrication cost increases
Solution Approach 1:
The patent combines multiple separate frame manufacturing processes into a single case body manufacturing process, reducing the number of fabrication steps, material handling operations, and assembly operations required. This merger significantly lowers fabrication cost while maintaining structural strength.
Solution Approach 2:
By removing the need to manufacture and assemble multiple separate frame plates (front plate, rear plate, side plate, lower plate, upper plate), the patent eliminates associated fabrication costs for each component and their interconnections, reducing overall manufacturing expense while preserving necessary strength.
4Ease of manufacture
If conventional electrical connection structure is used, then the battery pack can be assembled, but the energy density decreases and fabrication efficiency is reduced
Solution Approach 1:
The patent merges the electrical connection structure into a simplified configuration where battery cells are directly connected within the case body, eliminating complex intermediate connection components. This integration reduces the volume occupied by electrical connections and improves fabrication efficiency while maintaining assembly feasibility.
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 achieves improved energy density, strength, price competitiveness, and fabrication efficiency, along with enhanced cooling performance by simplifying the electrical connection structure and optimizing the cooling system.
Implementation Method 1
a thermally conductive member filled in a space between the cooling unit and the plurality of battery cells
Implementation Method 2
a cooling tube which is formed over a predetermined length along the lengthwise direction of the battery cell assembly and positioned between the plurality of battery cells, the cooling tube having a cooling channel for cooling water circulation inside
Data Source
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 on the battery cell assembly and electrically connected to the plurality of battery cells; a cooling unit below the busbar assembly and interposed between the plurality of battery cells along a lengthwise direction of the battery cell assembly; and a thermally conductive member disposed in a space between the cooling unit and the plurality of battery cells.