Battery Pack Lead Layout for Cooling Switch Heat
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Solution Overview
Problem
Existing battery packs face challenges in efficiently dissipating heat from switch devices and optimizing the electrical connections of battery cells, leading to potential interference and increased material costs.
Innovation Solution
A battery pack design that includes a case with alternating patterns of leads connected to tab plates, a barrier wall for fluid flow, and a switch device placement that enhances heat dissipation and reduces electrical interference, using a cooling fluid to cool both battery cells and heat-generating components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leads are arranged in conventional patterns connecting tab plates to circuit boards, then electrical connections are established, but electrical interference increases and material costs increase
Solution Approach 1:
The patent applies asymmetry by arranging first leads and second leads in alternating patterns along one side of the circuit board rather than symmetric patterns on opposite sides. This asymmetric arrangement reduces electrical interference between leads while maintaining reliable electrical connections from tab plates to the circuit board, directly resolving the contradiction between connection stability and interference reduction.
2Reliability
If switch devices are placed in conventional positions, then circuit functionality is achieved, but heat dissipation efficiency is insufficient
Solution Approach 1:
The patent introduces a cooling fluid as an intermediary substance that flows through channels in the circuit board to dissipate heat from switch devices. The cooling fluid acts as a thermal mediator, absorbing heat from the switch devices and transporting it away, thereby maintaining circuit functionality while significantly improving heat dissipation efficiency.
3Temperature
If cooling fluid channels are added to the circuit board, then heat dissipation from switch devices improves, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by designing the circuit board to simultaneously serve as both the electrical circuit carrier and the cooling fluid channel structure. The circuit board includes integrated cooling channels that allow cooling fluid to flow directly through it, enabling the same component to perform both electrical and thermal management functions, thus improving heat dissipation without proportionally increasing device complexity.
4Object-generated harmful factors
If leads are arranged in alternating patterns along one side of the circuit board, then electrical interference is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the lead connections into distinct groups (first leads and second leads) that are alternately arranged along the circuit board edge. This segmentation approach organizes the electrical connections in a systematic alternating pattern, which reduces electrical interference between adjacent leads while providing a clear manufacturing guide for lead placement, thereby balancing interference reduction with manufacturability.
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 improves heat dissipation from switch devices and reduces electrical interference, while optimizing material usage and reducing costs through efficient lead arrangements and fluid flow management.
Implementation Method 1
a case having an accommodation space in which the battery cells and a cooling fluid to cool the battery cells are configured to be accommodated
Data Source
AI summary
A battery pack includes: battery cells, each including first and second end portions that are opposite each other in a length direction; a case having an accommodation space in which the battery cells and a fluid to cool the battery cells are configured to be accommodated, the case including first and second covers respectively covering the first and second end portions; first and second tab plates respectively on the first and second covers and connected to the first and second end portions; a circuit board on the first tab plate; and a first lead and a second lead through which the first and second tab plates are connected to the circuit board, the first and second leads connected to a first side portion of the circuit board. An arrangement of the leads connected to electrodes of the battery cells is improved, and heat is efficiently dissipated from a switch device.