Battery Pack Busbar-Coupled Cooling Structure for Dense Cell Layout
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Solution Overview
Problem
Conventional battery packs face challenges with high manufacturing costs, complex assembly processes, and poor cooling performance due to the structural characteristics of their cell frames, which include multiple plates, making it difficult to arrange cooling units effectively.
Innovation Solution
A battery pack design featuring a busbar assembly on one side of the battery cells and a cooling unit between the cells, with a cooling tube and channel for fluid circulation, secured by fixing holders, and filled with a filler member to enhance stability and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cell frame including an assembly of plates is used to accommodate battery cells, then the structural strength is ensured, but the manufacturing cost increases and the assembly process becomes complex
Solution Approach 1:
The patent removes the complex plate assembly structure from the battery pack design. Instead of using multiple plates to form a cell frame, the invention uses a simplified single-piece lower cover that integrates the functions of support and accommodation, thereby reducing manufacturing complexity and cost while maintaining structural strength
Solution Approach 2:
The patent combines multiple functions into a single lower cover component. The lower cover simultaneously provides structural support, accommodates battery cells, and serves as a mounting base for cooling units and busbar assemblies, eliminating the need for separate plate assemblies and reducing overall device complexity
2Strength
If a cell frame including an assembly of plates is used, then the structural strength is ensured, but the cooling performance deteriorates due to difficulty in arranging cooling units
Solution Approach 1:
The patent removes the plate assembly structure that hindered cooling unit arrangement. By replacing it with a simplified lower cover design, the invention enables direct and effective placement of cooling units between battery cells, significantly improving cooling performance
Solution Approach 2:
The patent transitions from a frame-based structural approach to a base-plane approach. The lower cover provides a flat, stable base that allows cooling units to be arranged optimally in the horizontal plane between battery cells, enabling better thermal management without compromising structural integrity
3Quantity of substance
If multiple plates are assembled to form a cell frame, then the battery cells can be accommodated, but the manufacturing cost increases
Solution Approach 1:
The patent removes the multi-plate assembly structure and replaces it with a single-piece lower cover, thereby reducing the number of components, simplifying manufacturing processes, and lowering production costs while maintaining the ability to accommodate multiple battery cells
Solution Approach 2:
The patent combines the functions of multiple plates into a single lower cover component that can still accommodate multiple battery cells through its designed geometry and structure, thereby reducing manufacturing complexity and cost without sacrificing cell accommodation capacity
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 cooling performance, increases energy density, and enhances manufacturing efficiency by stabilizing the busbar assembly and increasing contact area with the cells, while reducing manufacturing costs.
Implementation Method 1
a cooling channel provided in the cooling tube and configured to circulate a cooling fluid for cooling the battery cells
Implementation Method 2
a cooling channel provided in the cooling tube and configured to circulate a cooling fluid for cooling the battery cells
Data Source
AI summary
A battery pack according to an embodiment of the present disclosure includes a plurality of battery cells, a busbar assembly disposed on one side of the plurality of battery cells and electrically connected to the plurality of battery cells, and a cooling unit disposed between the plurality of battery cells and secured to the busbar assembly.