Battery Pack Frame with Embedded Busbars and Thermal Plates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face challenges in easy manufacturing and scalability, as well as effective thermal management and voltage sensing, which are not adequately addressed by current designs.
Innovation Solution
The battery pack design incorporates embedded busbars and voltage sensing members within plastic frame assemblies, allowing for easy electrical coupling of modules and scalable configuration, along with thermally conductive plates for heat management, eliminating the need for separate interconnect circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate interconnect circuit boards are used for electrical coupling, then electrical connection is achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the electrical connection function into the frame assembly by integrating busbars directly into the frame structure. The frame assembly includes conductive elements that serve both structural support and electrical connection purposes, eliminating the need for separate interconnect circuit boards and reducing overall device complexity.
Solution Approach 2:
The frame assembly performs multiple functions simultaneously: it provides structural support, thermal management through integrated cooling channels, and electrical connection through embedded busbars. This multi-functionality reduces the number of separate components needed and simplifies manufacturing.
2Temperature
If thermally conductive plates are added for thermal management, then heat dissipation improves, but device complexity increases
Solution Approach 1:
The thermal management system is merged with the frame assembly by integrating thermally conductive plates and cooling channels directly into the frame structure. This integration allows the frame to serve both structural and thermal management functions simultaneously, avoiding the addition of separate thermal management components.
Solution Approach 2:
The frame assembly utilizes composite construction combining thermally conductive materials with structural components. The thermally conductive plates are integrated into the frame to create a composite structure that provides both mechanical strength and efficient heat dissipation.
3Adaptability or versatility
If voltage sensing members are embedded in frame assemblies, then voltage sensing is integrated, but manufacturing complexity increases
Solution Approach 1:
The voltage sensing members are merged with the frame assembly by embedding them directly into the frame structure during manufacturing. This integration allows the frame to provide both structural support and voltage sensing functionality, reducing the number of separate components and simplifying assembly.
4Adaptability or versatility
If modular battery modules are designed for scalability, then adaptability improves, but manufacturing precision requirements increase
Solution Approach 1:
The battery system is divided into modular battery modules that can be independently manufactured and then assembled into larger configurations. Each module contains complete functional elements (battery cells, frame assembly with integrated busbars and cooling channels), allowing for standardized production and easy scaling by simply adding or removing modules.
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 design enables easy assembly and scalability of battery modules, efficient thermal management through embedded thermally conductive plates, and integrated voltage sensing, enhancing the overall performance and manufacturing efficiency of the battery pack.
Implementation Method 1
a first thermally conductive plate, coupled to the first, second, third and fourth side walls of the first rectangular ring-shaped body and adapted to enclose the first central space
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery pack includes a first battery module having first and second battery frame assemblies and first and second battery cells. The first battery frame assembly has a plastic frame member, a thermally conductive plate, a busbar, and a voltage sensing member. The plastic frame member has a rectangular ring-shaped body. The thermally conductive plate is coupled to rectangular ring-shaped body. The busbar has a first post and a first conductive body coupled to the first post. The first post extends outwardly from the plastic frame member, and the first conductive body extends through the rectangular ring-shaped body. The voltage sensing member has a first sensing post and a first sensing body. The first sensing post extends outwardly from the rectangular ring-shaped body.