Integrated Battery Pack Frame for Higher Energy Density
Find Innovative SolutionsGenerate Solutions
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 multiple plates in the cell frame structure, 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 and potting resin to enhance energy density and strength, along with a cooling system for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cell frame structure including an assembly of multiple plates is used, then the strength and structural support are improved, but the fabrication cost increases and the assembly process becomes complex
Solution Approach 1:
The patent merges multiple separate plates (front plate, rear plate, side plates, lower plate, upper plate) into a single integrated cell frame structure. This unified structure maintains the necessary structural support and strength while eliminating the complex assembly process of joining multiple plates together, thereby reducing fabrication cost and assembly complexity
Solution Approach 2:
The integrated cell frame structure serves multiple functions simultaneously: it provides structural support, accommodates battery cells, and replaces the need for separate assembly of multiple plates. This multi-functional design reduces the overall device complexity while maintaining strength requirements
2Strength
If a cell frame structure including an assembly of multiple plates is used, then the structural support is improved, but the total size increases and energy density decreases
Solution Approach 1:
By integrating multiple plates into a single cell frame structure, the patent eliminates the gaps and overlap areas between separate plates, thereby reducing the total volume occupied by the structural components. This volume reduction increases the proportion of active materials, thereby improving energy density while maintaining structural support
3Stability of the object's composition
If conventional battery pack structure is used, then the structural integrity is maintained, but the fabrication cost increases and price competitiveness decreases
Solution Approach 1:
The patent combines multiple separate structural components into a single integrated cell frame, which reduces the number of manufacturing steps, material joints, and assembly operations. This simplification lowers fabrication costs while the integrated design ensures structural integrity is maintained through continuous material structure
4Strength
If multiple plates are assembled to form cell frame, then the structural support is improved, but the fabrication efficiency decreases
Solution Approach 1:
By integrating multiple plates into a single cell frame structure, the patent reduces the number of assembly operations from joining multiple separate plates to a single-component installation. This dramatically improves fabrication efficiency and productivity while the integrated structure maintains the necessary structural support through its unified design
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 achieves increased energy density, improved cooling performance, and enhanced fabrication efficiency, resulting in better price competitiveness for battery packs and vehicles using these packs.
Implementation Method 1
a cooling unit between the plurality of battery cells
Implementation Method 2
at least one refrigerated wall set adherent to one of said at least two conductive plates
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery pack according to an embodiment of the present disclosure includes a battery cell assembly comprising 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 which partitions the plurality of battery cells together with the cooling unit.