Cylindrical Cell Block Assembly for Dense Battery Module Cooling
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Solution Overview
Problem
Conventional battery modules and packs face inefficiencies in assembly due to varying shapes and forms, leading to compatibility and expandability issues, and increased dead space in cylindrical cell configurations, which affects weight, slimness, and energy density.
Innovation Solution
A battery cell assembly comprising cylindrical cell blocks with a block cover, cooling plate, heat transfer member, and heat insulating members, where the cell blocks are shaped to couple in a block type, with bus bar members for electrical connection and thermal interface materials for efficient heat transfer, minimizing dead space and enhancing compatibility and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cylindrical cells are assembled in conventional configurations, then the battery module can be constructed, but dead space occurs between cells which deteriorates weight, slimness and energy density
Solution Approach 1:
The patent applies curvature by designing the cooling plate with a curved surface that conforms to the cylindrical shape of the battery cells. This curved cooling plate eliminates dead space between the cylindrical cells and the cooling plate, improving energy density by maximizing the usable volume within the battery module while maintaining effective thermal contact with all cells.
2Adaptability or versatility
If the assembly type of battery cells is changed according to model type, then the battery module can be customized, but process efficiency deteriorates due to lack of compatibility and expandability
Solution Approach 1:
The patent implements universality through a standardized block-type assembly structure where battery cells are arranged in modular blocks with uniform dimensions and connection interfaces. This block-type assembly can be universally applied across different battery module models, allowing the same assembly process and components to be used for various configurations, thereby improving process efficiency while maintaining model compatibility and expandability.
3Adaptability or versatility
If conventional battery modules are configured with varying assembly types, then different model requirements can be met, but manufacturing complexity increases and efficiency decreases
Solution Approach 1:
The patent applies segmentation by dividing the battery module into standardized block-type assemblies, each containing a specific number of battery cells arranged in a uniform configuration. These modular blocks can be easily assembled and disassembled, reducing manufacturing complexity while maintaining the flexibility to configure different model requirements by simply varying the number and arrangement of blocks.
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 solution enables a more efficient and compatible battery cell assembly that improves manufacturing process efficiency, reduces dead space, and enhances energy density and slimness, allowing for a more versatile and compact battery module and pack design.
Implementation Method 1
a heat transfer member disposed between the cooling plate and the plurality of cylindrical cell blocks and having a plurality of thermal interface materials corresponding to bottom portions of the plurality of cylindrical cells
Data Source
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AI summary
A battery cell assembly includes: a plurality of cylindrical cell blocks, each including a plurality of cylindrical cells; a block cover configured to cover an upper side of the plurality of cylindrical cell blocks and electrically connect the plurality of cylindrical cell blocks; a cooling plate located opposite to the block cover and disposed at a lower side of the plurality of cylindrical cell blocks; and a heat transfer member disposed between the cooling plate and the plurality of cylindrical cell blocks and having a plurality of thermal interface materials corresponding to bottom portions of the plurality of cylindrical cells.