Integrated Battery Pack Structure for Higher Energy Density Cooling
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Solution Overview
Problem
Conventional battery packs face challenges with increased fabrication costs, complex assembly processes, reduced energy density, and size due to the use of a cell frame structure composed of multiple plates, which affects price competitiveness and efficiency.
Innovation Solution
A battery pack design incorporating a battery cell assembly with a busbar assembly, cooling unit, and cell accommodation unit, utilizing a filling member made of potting resin to cover and support the assembly, along with a cell support unit and reinforcement structures, enhancing energy density and cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cell frame structure including an assembly of multiple plates is used to accommodate battery cells, then the battery pack structure is established and provides support, but the fabrication cost increases and the assembly process becomes complex
Solution Approach 1:
The patent combines multiple separate structural components (front plate, rear plate, side plates, lower plate, upper plate) into a single integrated cell frame structure. This merging eliminates the need for complex assembly of multiple plates while maintaining the structural support function, thereby reducing fabrication complexity and cost.
Solution Approach 2:
The integrated cell frame structure serves multiple functions simultaneously: it accommodates battery cells, provides structural support, and facilitates assembly. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly process while maintaining strength.
2Strength
If a cell frame structure including an assembly of multiple plates is used to accommodate battery cells, then the battery pack structure is established and provides support, but the total size increases and energy density decreases
Solution Approach 1:
By merging multiple plates into a single integrated structure, the patent eliminates gaps and redundant materials between separate components. This reduces the overall volume occupied by the structural framework, thereby increasing the space available for battery cells and improving energy density while maintaining structural support.
3Ease of manufacture
If conventional plate assembly structure is used, then battery cells are accommodated, but fabrication cost increases and price competitiveness decreases
Solution Approach 1:
The patent merges multiple separate plates into a single integrated structure, which simplifies the fabrication process by reducing the number of components that need to be manufactured, transported, and assembled. This merging reduces fabrication complexity and associated costs, improving price competitiveness.
4Temperature
If cooling unit is added between battery cells, then cooling performance is enhanced, but device complexity and fabrication cost increase
Solution Approach 1:
The patent integrates the cooling unit into the cell frame structure, allowing it to serve dual purposes: providing structural support and delivering cooling functionality. This integration reduces the need for separate cooling components and simplifies the overall structure, thereby enhancing cooling performance without proportionally increasing device complexity.
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 new design improves energy density, strength, price competitiveness, and fabrication efficiency while providing enhanced cooling performance, making it suitable for vehicles.
Implementation Method 1
a cooling unit between the plurality of battery cells
Implementation Method 2
cooling unit between the plurality of battery cells
Implementation Method 3
a filling member filled in a space between the cooling unit and the plurality of battery cells
Data Source
AI summary
Discussed is a battery pack that can include a battery cell assembly including a plurality of battery cells, a busbar assembly on one side of the battery cell assembly, a cooling unit between the plurality of battery cells, and a cell accommodation unit configured to partition the plurality of battery cells together with the cooling unit.