Battery Pack Bus Bar and Cooling Unit Layout for Cell Heat Dissipation
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Solution Overview
Problem
Rechargeable batteries generate significant heat during charging and discharging, which can lead to damage if not effectively dissipated, especially in battery packs with multiple cells.
Innovation Solution
A rechargeable battery pack design featuring a cooling unit within the housing, a bus bar system that includes rib protrusions to enhance heat transfer from the battery cells to the cooling unit, and a holder structure to secure the cells, facilitating efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple unit battery cells are connected in parallel or series to achieve large capacity, then the battery pack provides higher power output, but heat generation increases and becomes difficult to dissipate
Solution Approach 1:
The battery pack is divided into multiple independent battery cell compartments, each with its own cooling channels. This segmentation allows heat from each cell to be dissipated independently, preventing heat accumulation while maintaining high power output from multiple cells connected in parallel or series.
Solution Approach 2:
A cooling medium (such as water or coolant) is introduced as an intermediary substance that flows through cooling channels between battery cells. This medium absorbs heat generated by the battery cells during high-power operation and transports it away, enabling sustained high power output without excessive temperature rise.
2Temperature
If a cooling unit is added to dissipate heat, then temperature control improves, but device complexity increases
Solution Approach 1:
The cooling unit is merged with the battery pack housing structure, where cooling channels are integrated into the housing walls and separators between cells. This combination eliminates the need for separate cooling components, reducing overall device complexity while maintaining effective temperature control.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support, electrical insulation, and thermal management through integrated cooling channels. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure while achieving effective temperature control.
3Temperature
If cooling channels are integrated into the housing, then heat dissipation efficiency increases, but manufacturing complexity increases
Solution Approach 1:
Cooling channels are pre-formed into the housing structure during the molding process using inserts or conformal cooling techniques. This preliminary action integrates the cooling function into the basic manufacturing step, avoiding the need for separate post-processing operations and reducing overall manufacturing complexity despite the enhanced heat dissipation capability.
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 effectively transfers and dissipates heat generated by the battery cells, preventing damage and ensuring stable operation by maintaining optimal temperature levels.
Implementation Method 1
a cooling unit in the battery housing under the second bus bar configured to allow a cooling medium to flow therein for cooling the unit battery cells
Implementation Method 2
allow a cooling medium to flow therein for cooling the unit battery cells
Data Source
AI summary
A rechargeable battery pack may include: a battery housing including an inner space; a series of unit battery cells accommodated in the inner space; a first bus bar configured to electrically connect the unit battery cells above the unit battery cells; a second bus bar configured to electrically connect the unit battery cells under the unit battery cells and contact a bottom plate of the battery housing in the inner space; and a cooling unit in the battery housing under the second bus bar configured to accommodate a cooling medium to flow therein for cooling the unit battery cells.