Integrated Battery Pack Side 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 structures made of multiple plates, leading to increased size and manufacturing costs.
Innovation Solution
A battery pack design incorporating a bus bar assembly, cooling unit, side structure unit, and filling member made of potting resin, which supports battery cells and improves rigidity, energy density, and 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 merges the cell frame structure from multiple separate plates into a single integrated frame body. This unification maintains the necessary rigidity while eliminating the complexity of assembling multiple plates, directly resolving the contradiction between structural strength and assembly simplicity
Solution Approach 2:
The integrated frame body serves multiple functions simultaneously: it provides structural rigidity, acts as a containment structure for battery cells, and eliminates the need for separate assembly of multiple plates. This multi-functionality approach resolves the contradiction by consolidating what would otherwise require multiple components
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:
By combining multiple plates into a single integrated frame body, the patent reduces the number of manufacturing steps, materials needed, and assembly operations. This consolidation maintains rigidity while significantly reducing manufacturing cost through simplified production processes
Solution Approach 2:
This principle is not applicable to the current patent context as it relates to visual properties rather than structural or manufacturing characteristics
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 integration of multiple plates into a single frame body eliminates the gaps and overlapping structures required when assembling separate plates. This merging reduces the overall volume occupied by the frame structure while maintaining its structural support function, directly addressing the contradiction between strength and compactness
Data Source
AI summary
Discussed is a battery pack, including a plurality of battery cells, and a side structure unit configured to accommodate a cooling unit and the plurality of battery cells and configured to form a first section of an outer surface of the battery pack. The side structure unit includes a main plate formed to have a predetermined length along the longitudinal direction of the battery pack, and accommodates a first group of the plurality battery cells at a first side and a second group of the plurality of battery cells at a second side that is opposite to the first side, and each of the first side and the second side of the main plate includes a plurality of inter-wings that separate the plurality of battery cells.