Prismatic Battery Module Structure With Integrated Cooling Base
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Solution Overview
Problem
Existing battery packs and modules face challenges in achieving a cost-effective, space-efficient, and robust configuration that is easily scalable, with prior solutions often requiring numerous parts and inadequate terminal accessibility.
Innovation Solution
A battery module design featuring prismatic battery cells stacked with side terminals, supported by longitudinally extending beam members and crossbeam members, a cooling plate bottom member, and a top cover, which forms a receiving space for the cells and provides structural rigidity and cooling, allowing for efficient stacking and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a traditional battery pack configuration is used with separate support structures and cooling plates, then structural stability is achieved, but device complexity increases and space efficiency decreases
Solution Approach 1:
The patent combines the support function and cooling function into a single integrated bottom member structure. The bottom member simultaneously serves as the structural support for stacking battery cells and as the cooling plate for thermal management, eliminating the need for separate support structures and cooling plates. This merging reduces device complexity while maintaining structural stability and cooling effectiveness.
Solution Approach 2:
The bottom member is designed with multi-functionality, serving both as a structural support element and as a cooling plate. This universal component performs multiple functions (support, cooling, and structural rigidity provision) that traditionally required separate dedicated components, thereby reducing the overall part count while maintaining system reliability.
2Quantity of substance
If battery cells are stacked in conventional configurations, then capacity is increased, but terminal accessibility deteriorates
Solution Approach 1:
The patent utilizes the vertical dimension (height direction) for stacking battery cells to increase capacity, while the bottom member extends in the longitudinal direction to provide accessible terminals at the lower end. This dimensional arrangement allows cells to be stacked vertically for higher capacity while terminals remain accessible horizontally at the bottom, resolving the conflict between capacity and accessibility.
3Strength
If more parts are used for support and cooling structures, then structural rigidity is improved, but manufacturing cost increases
Solution Approach 1:
By merging the support structure and cooling plate into a single bottom member, the patent reduces the total number of parts that need to be manufactured, assembled, and secured. This integration lowers manufacturing complexity and cost while the bottom member itself is designed with sufficient structural rigidity to provide adequate support for the stacked battery cells.
4Temperature
If the cooling plate is separated from the support structure, then cooling efficiency is optimized, but space efficiency decreases
Solution Approach 1:
The bottom member integrates the cooling plate function directly into the support structure, with the bottom member forming both the structural base and the cooling surface. This integration maintains effective cooling contact with the battery cells while maximizing space utilization by eliminating gaps or separate components between support and cooling functions.
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 a space-efficient, reliable, and robust battery module that is easily scalable, with improved terminal accessibility and reduced part count, enhancing assembly and cooling efficiency.
Implementation Method 1
a cooling plate bottom member, provided at a bottom portion of the first and second separate longitudinally extending beam members and the plurality of separate crossbeam members
Data Source
AI summary
A battery module for a battery pack includes a plurality of battery cells, having at least one group of stacked prismatic battery cells which are stacked next to each other in the longitudinal direction. A first and a second separate longitudinally extending beam member are offset from each other in the width direction. A plurality of separate crossbeam members are offset from each other in the longitudinal direction, wherein each crossbeam member extends in the width direction and wherein the plurality of separate crossbeam members mechanically connects the first and second separate longitudinally extending beam members together. A cooling plate bottom member is provided at a bottom portion of the first and second separate longitudinally extending beam members and the plurality of separate crossbeam members.