Battery Pack Cross Beam Cooling Structure for Higher Energy Density
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Solution Overview
Problem
Conventional battery packs face challenges with increased manufacturing costs, complex assembly processes, reduced price competitiveness, and lower energy density due to their multi-plate cell frame structure, which also results in larger size and decreased fabrication efficiency.
Innovation Solution
A battery pack design featuring a base plate and a cross beam unit with integrated cooling water channels, where the cross beam unit is positioned between the base plate and cover plate to support and secure battery cells, enhancing strength and energy density while eliminating the need for a conventional cell frame, thus simplifying assembly and reducing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional multi-plate cell frame structure is used to support battery cells, then the battery pack achieves adequate structural support, but the manufacturing cost increases and assembly process complexity increases
Solution Approach 1:
The cross beam unit merges the support function and cooling function into a single integrated component. The cross beam unit includes cooling water channels formed within its structure, eliminating the need for separate cooling plates and reducing the number of parts from multiple plates to a single unified component that provides both mechanical support and thermal management.
Solution Approach 2:
The cross beam unit serves multiple functions simultaneously: it provides structural support for the battery cells, acts as a cooling component with integrated water channels, and serves as a mounting structure. This multi-functionality reduces the overall component count and simplifies the assembly process while maintaining structural integrity.
2Strength
If a conventional multi-plate cell frame structure is used to support battery cells, then the battery pack achieves adequate structural support, but the manufacturing cost increases
Solution Approach 1:
The cross beam unit merges the support function and cooling function into a single integrated component. The cross beam unit includes cooling water channels formed within its structure, eliminating the need for separate cooling plates and reducing the number of parts from multiple plates to a single unified component that provides both mechanical support and thermal management.
Solution Approach 2:
The cross beam unit serves multiple functions simultaneously: it provides structural support for the battery cells, acts as a cooling component with integrated water channels, and serves as a mounting structure. This multi-functionality reduces the overall component count and simplifies the assembly process while maintaining structural integrity.
3Strength
If a conventional multi-plate cell frame structure is used to support battery cells, then the battery pack achieves adequate structural support, but the total size increases and energy density decreases
Solution Approach 1:
The cross beam unit merges the support function and cooling function into a single integrated component. The cross beam unit includes cooling water channels formed within its structure, eliminating the need for separate cooling plates and reducing the number of parts from multiple plates to a single unified component that provides both mechanical support and thermal management.
Solution Approach 2:
The invention extracts and eliminates unnecessary components from the conventional multi-plate structure. By removing redundant plates and integrating the cooling function into the cross beam unit, the design reduces the overall volume occupied by the support structure, thereby increasing the energy density of the battery pack.
4Strength
If a conventional multi-plate cell frame structure is used to support battery cells, then the battery pack achieves adequate structural support, but the fabrication efficiency decreases
Solution Approach 1:
The cross beam unit merges the support function and cooling function into a single integrated component. The cross beam unit includes cooling water channels formed within its structure, eliminating the need for separate cooling plates and reducing the number of parts from multiple plates to a single unified component that provides both mechanical support and thermal management.
Solution Approach 2:
The cross beam unit serves multiple functions simultaneously: it provides structural support for the battery cells, acts as a cooling component with integrated water channels, and serves as a mounting structure. This multi-functionality reduces the overall component count and simplifies the assembly process while maintaining structural integrity.
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 solution results in a battery pack with improved energy density, strength, price competitiveness, and fabrication efficiency, as well as simplified cooling without additional structures like heat sinks, leading to increased energy density and reduced size.
Implementation Method 1
The cross beam unit may include a cooling water channel to cool the plurality of battery cells
Data Source
AI summary
A battery pack configured to be mounted in a vehicle according to an embodiment of the present disclosure includes a plurality of battery cells; a base plate supporting the plurality of battery cells; and a cross beam unit positioned over a predetermined length along a widthwise direction of the base plate, and interposed between the plurality of battery cells in a lengthwise direction of the base plate to attach and fix the facing battery cells in the lengthwise direction.