Integrated Battery Pack Structure for Rigidity and Cooling
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Solution Overview
Problem
Conventional battery packs face issues with cost competitiveness, manufacturing efficiency, energy density, and cooling performance due to their complex frame structure made of multiple plates, which increases size and manufacturing costs.
Innovation Solution
A battery pack design featuring a bus bar assembly, cooling unit, side structure unit, and filling member made of potting resin, which secures rigidity, enhances energy density, and improves cooling performance while simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cell frame structure configured as an assembly of multiple plates is used, then rigidity is secured, but manufacturing cost increases and assembly process becomes complicated
Solution Approach 1:
The patent combines multiple separate plate components (front plate, rear plate, side plates, lower plate, upper plate) into a single integrated cell frame structure. This merging eliminates the need for complex assembly of multiple plates while maintaining the rigidity and structural support functions, directly resolving the contradiction between securing rigidity and simplifying the assembly process.
2Strength
If a conventional cell frame structure configured as an assembly of multiple plates is used, then rigidity is secured, but manufacturing cost increases
Solution Approach 1:
The integration of multiple plates into a single cell frame structure reduces manufacturing cost by eliminating the need to produce, inventory, and assemble multiple separate components. The single integrated structure can be manufactured more efficiently while providing the same rigidity and structural support, directly addressing the cost competitiveness issue.
3Strength
If a conventional cell frame structure configured as an assembly of multiple plates is used, then structural support is provided, but the size of the entire battery pack is increased
Solution Approach 1:
The single integrated cell frame structure eliminates the gaps and connection interfaces required between multiple separate plates, thereby reducing the overall volume occupied by the frame structure. This merging approach maintains structural support functionality while minimizing the space taken by the frame, thus increasing energy density.
4Strength
If multiple plates are assembled to form a cell frame, then rigidity is achieved, but the number of components and assembly steps increases
Solution Approach 1:
By merging five separate plate assemblies into one integrated cell frame, the patent reduces the number of assembly steps from assembling multiple plates to simply installing a single frame structure. This significantly improves manufacturing efficiency and productivity while maintaining the rigidity required for structural support.
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 cost competitiveness, and enhanced manufacturing efficiency with better cooling performance, addressing the limitations of conventional battery packs.
Implementation Method 1
The filling member may be made of a potting resin.
Implementation Method 2
a cooling unit disposed at the second side of the bus bar assembly and arranged between the plurality of battery cells
Data Source
AI summary
Discussed is a battery pack, including a plurality of battery cells, a bus bar assembly electrically connected to the plurality of battery cells, a side structure unit configured to accommodate the plurality of battery cells and configured to form a first section of an outer surface of the battery pack, and a filling member configured to form a second section of the outer surface of the battery pack together with the first section of the outer surface of the battery pack formed by the side structure unit, the filling member further being filled in a space between the plurality of battery cells.