Energy Storage Pack Assembly With Integrated Cooling and Filler Fixation
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Solution Overview
Problem
The modular design of battery packs is hindered by complexity in connectivity, structural integrity, weight, and cost, leading to inefficiencies in energy density, storage capacity, and potential failure points, with a need for a more streamlined approach.
Innovation Solution
A method and apparatus for assembling energy storage packs by stacking energy storage members and cooling members alternately within a frame structure, applying pressure to fixate them, and using a filler to secure their position, eliminating the need for preassembled modules and enhancing mechanical and thermal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modular design with preassembled battery modules is used, then assembly flexibility and scalability are improved, but device complexity and number of connectors increase
Solution Approach 1:
The patent merges the battery cell support function and cooling function into a single integrated structure. The cooling member is directly coupled to the battery cell holder, eliminating the need for separate cooling pipes and connectors that would be required in a modular design. This integration reduces the number of connectors while maintaining assembly flexibility.
Solution Approach 2:
The cooling member serves multiple functions: it provides thermal management for battery cells and simultaneously acts as a structural support element. This multi-functionality reduces the need for separate structural components and connectors, thereby reducing device complexity while maintaining design versatility.
2Strength
If extensive connecting cables and structural components are used for modular assembly, then structural integrity is improved, but weight increases
Solution Approach 1:
The patent combines the structural support function and cooling function into a single integrated cooling member. This eliminates the need for separate structural components and connecting cables, reducing weight while maintaining structural integrity through the unified design.
Solution Approach 2:
The patent extracts and eliminates unnecessary connecting cables and redundant structural components from the modular assembly. By using the cooling member as both a structural and thermal management component, the design removes excess weight while preserving structural integrity.
3Adaptability or versatility
If multiple connectors and connecting cables are used for modular connectivity, then connectivity between modules is improved, but reliability decreases due to more failure points
Solution Approach 1:
The patent merges the electrical connectivity function and thermal management function into a single integrated cooling member. This eliminates multiple connectors and connecting cables, reducing the number of potential failure points while maintaining module connectivity through the unified structure.
4Productivity
If preassembled modular battery modules are used, then manufacturing scalability is improved, but manufacturing cost increases
Solution Approach 1:
The patent integrates the cooling member and battery cell holder into a single component, reducing the number of parts that need to be manufactured and assembled. This simplification lowers manufacturing costs while maintaining scalability, as fewer components mean fewer assembly steps and reduced inventory complexity.
Solution Approach 2:
The multi-functional cooling member reduces the overall part count in the battery pack assembly. This universality allows for simpler manufacturing processes and lower costs, while the modular nature of the integrated unit preserves manufacturing scalability.
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 method reduces assembly steps, weight, and costs while improving cooling capacity and performance, ensuring precise positioning and increased lifetime of the energy storage pack.
Implementation Method 1
Releasing the assembling pressure after a predetermined curing time and/or curing condition of the filler
Implementation Method 2
applying, by a pressure member, a preferably equally distributed assembling pressure on at least one side of the energy storage pack for at least temporarily fixating at least the plurality of energy storage members and the plurality of cooling members inside the frame structure
Implementation Method 3
a plurality of cooling members for cooling the plurality of energy storage member
Data Source
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AI summary
A method for assembling an energy storage pack (200), the method comprising providing (S1) the energy storage pack (200) having a frame structure (202), a plurality of energy storage members (204) and a plurality of cooling members (206) for cooling the plurality of energy storage members (204); applying (S2) an assembling pressure (P) on at least one side (210) of the energy storage pack (200) for at least temporarily fixating at least the plurality of energy storage members (204) and the plurality of cooling members (206) in a predefined assembling position; dispensing (S3) a filler (212) inside the frame structure (202), when at least the plurality of energy storage members (204) and the plurality of cooling members (206) are fixated in the predefined assembling position; and releasing (S4) the assembling pressure (P) to obtain the assembled energy storage pack (200).