Battery Pack Module Support for PCB Height Variation and Heat Transfer

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Solution Overview

Problem

Conventional battery packs face challenges in supporting circuit modules with varying element heights, leading to complex internal structures, increased manufacturing costs, and reduced heat dissipation efficiency.

Innovation Solution

A battery pack design featuring a module support part made of elastic material, which is inserted into the pack frame to support the circuit module, allowing for elastic deformation and improved heat transfer between the circuit module and the pack frame.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If support ribs are provided at various heights to correspond to the arrangement and heights of the elements, then the circuit module can be stably supported, but the internal structure of the pack frame becomes complicated and the manufacturing cost increases

Engineering Contradiction:

Improvestability of circuit module supportVSAvoidinternal structure of pack frame

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The support function is segmented from the pack frame structure. Instead of integrating support ribs of various heights into the pack frame, a separate support structure is used that can be independently configured and installed, simplifying the pack frame while maintaining support stability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure uses standardized parameters (uniform rib heights, regular spacing) rather than varying parameters (different heights for each element position). This standardization simplifies manufacturing while the modular design allows adaptation to different element arrangements

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the structure of the module seating part is changed according to the design of the circuit module, then the circuit module can be properly supported, but a new pack frame must be manufactured

Engineering Contradiction:

Improveadaptability to circuit module designVSAvoidmanufacturing of pack frame

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The support structure is made dynamically adaptable through its modular design. The same basic structure can be configured in different ways (different numbers of support ribs, different spacing) to accommodate various circuit module designs, eliminating the need for custom pack frames

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The support structure is designed as a universal component that can serve multiple circuit module configurations. The standardized modular design allows one support structure type to accommodate various element arrangements and heights, reducing the variety of pack frames needed

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If spaces are provided between the circuit module and the pack frame, then the circuit module can be accommodated, but convection occurs by the heat generated and heat dissipation efficiency is lowered

Engineering Contradiction:

Improveaccommodation of circuit moduleVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The support ribs serve as intermediary thermal conduction paths between the circuit module and pack frame. Instead of relying on convection through spaces, the support ribs directly conduct heat away from the circuit module elements to the pack frame, improving heat dissipation efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The thermal management mechanism is replaced from convection-based (fluid/gas movement in spaces) to conduction-based (direct thermal contact through support ribs). This substitution eliminates the need for convective spaces while maintaining accommodation functionality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 module support part simplifies the pack frame structure, reduces manufacturing costs, and enhances heat dissipation efficiency by transferring heat generated in the circuit module to the pack frame.

Implementation Method 1

the heat generated in the circuit module can be transferred to the pack frame through the module support part

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a module support part inserted into the module seating part to support the circuit module and configured to be elastically deformable upon contacting the element components

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250055116A1Battery pack

Publication Date: 2025.02.13 LG ENERGY SOLUTION LTD

AI summary

Discussed is a battery pack that may include at least one battery cell, a circuit module having element components mounted on a mounting surface and electrically connected to the at least one battery cell, a pack frame having a cell seating part in which the at least one battery cell is seated and a module seating part on which the circuit module is seated, and a module support part inserted into the module seating part to support the circuit module and provided to be elastically deformable upon contacting the element components.