Modular Battery Pack Frame Assembly With External Cooling Sealing
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Solution Overview
Problem
Conventional battery modules face challenges in design flexibility and manufacturing efficiency due to the need for high-output and large-capacity batteries, with limitations in scalability, serviceability, and recycling, and are prone to electrical errors.
Innovation Solution
A battery pack design that eliminates welding by using a base plate with integrated cooling passages and frames connected by fastening members, featuring a refrigerant circulation system and sealing members to prevent electrical errors and facilitate easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding process is used to connect frames, then structural strength is improved, but manufacturing complexity and time are increased
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical fastening system using fastening members. This substitution eliminates the complexity and time consumption of welding while maintaining structural integrity through mechanical connection, directly resolving the contradiction between structural strength and manufacturing efficiency.
Solution Approach 2:
The frame structure is divided into modular sections connected by fastening members rather than being welded as a single integrated structure. This segmentation allows for easier assembly, disassembly, and manufacturing while maintaining overall structural strength, thereby improving productivity without sacrificing strength.
2Strength
If welding process is used to connect frames, then structural strength is improved, but assembly and disassembly difficulty are increased
Solution Approach 1:
The patent replaces the irreversible welding process with reversible mechanical fastening using fastening members. This allows the frame structure to be easily assembled and disassembled while maintaining structural strength, directly resolving the contradiction between strength and ease of repair.
Solution Approach 2:
The connection system transitions from a static, permanent weld to a dynamic, reversible mechanical connection. The fastening members can be easily engaged and disengaged, providing adaptability for assembly, disassembly, and maintenance operations while preserving structural integrity during operation.
3Temperature
If cooling passage is formed inside base plate, then cooling efficiency is improved, but electrical error risk is increased
Solution Approach 1:
The patent extracts the cooling passage from the base plate interior and relocates it to the exterior surface. This extraction maintains cooling efficiency through direct thermal contact with battery modules while eliminating the risk of electrical errors by removing conductive elements from potential electrical contact zones.
Solution Approach 2:
The base plate acts as an intermediary thermal conductor that transfers heat from battery modules to the externally formed cooling passage. This mediation allows efficient heat dissipation while maintaining electrical isolation, as the cooling fluid flows in an external channel rather than through the base plate material itself.
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 simplifies the structure, enhances manufacturing efficiency, allows for easy design changes, and prevents electrical errors through external cooling, ensuring stable operation and easy maintenance.
Implementation Method 1
a base plate configured to include a cooling passage through which a refrigerant for cooling a plurality of battery modules is circulated by contacting the battery modules with a first surface
Data Source
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AI summary
A battery pack is disclosed. The battery pack includes a base plate configured to include a cooling passage through which a refrigerant for cooling a plurality of battery modules is circulated by contacting the battery modules with a first surface, a lower cover configured to cover a second surface of the base plate, a frame portion installed on an upper side of a first surface of the base plate to accommodate the battery modules therein and to couple a plurality of frames to each other by a fastening member, and an upper cover covering an upper portion of the frame portion. Herein, spaces between the frames constituting the frame portion may be sealed by a sealing member.