Integrated electrical and thermal busbar for battery packs

Abstract

The present disclosure relates to an integrated electrical and thermal busbar system designed for cylindrical cell battery packs. The system comprises a first busbar (1) and a second busbar (3) interfacing with the positive and negative terminals of a plurality of cylindrical cells (2) via resistance welding. A central connecting rod (5), constructed from high-conductivity materials such as copper or aluminum, bridges these busbars to ensure electrical continuity and facilitate heat transfer. A thermal interface material (4) is strategically positioned to fill voids between the cylindrical cells (2), the central connecting rod (5), and a heat dissipation unit (7), which may be a cold plate or heat sink, thereby optimizing thermal conductivity. The assembly is enclosed within a casing (6) that provides structural integrity and protection. The central connecting rod (5) also functions as a heating element in low-temperature conditions, enhancing the system's versatility.

Description

FORM 2THE PATENTS ACT, 1970.(39 of 1970)&THE PATENT RULES, 2003COMPLETE SPECIFICATION(See Section 10 and Rule 13)Title of invention:INTEGRATED ELECTRICAL AND THERMAL BUSBAR FOR BATTERY PACKSAPPLICANT:ENCRATE PRIVATE LIMITEDAn Indian CompanyHaving address:SR. No-277 / 3 / 1, FL No(B) 103, NR Janardan,Swami Ashram Road, NimaiNavshatra, Nashik - 422003The following specification particularly describes the invention and the manner in which it is to be performed.FIELD OF THE INVENTION

[0001] The present disclosure generally relates to the field of battery technology, and more particularly to an integrated electrical and thermal busbar system designed to enhance the efficiency and reliability of cylindrical cell battery packs by addressing challenges in electrical connectivity and thermal management.BACKGROUND

[0002] Cylindrical cell battery packs are essential for numerous applications, such as electric vehicles, consumer electronics, and energy storage systems. These battery packs encounter significant challenges in achieving efficient connectivity and thermal regulation. Conventional systems often require separate components for electrical connections and heat dissipation, leading to increased complexity, weight, and costs. Furthermore, ensuring effective performance at low temperatures and efficient heat transfer during operation remains a vital concern.

[0003] Lithium-ion (Li-ion) batteries, particularly in their cylindrical shape, are common due to their high energy density, long cycle life, and relatively low self-discharge rates. Despite their benefits, cylindrical cells pose specific challenges in the assembly of battery packs, particularly with electrical and thermal integration. Traditional techniques, such as wire bonding and resistance welding, have limitations due to spatial constraints and reliability challenges. These methods frequently result in high rates of failure and unreliable connections, complicating design and reducing efficiency.

[0004] Current industry solutions usually address either electrical or thermal integration problems in isolation, often resulting in compromises that negatively affect battery performance and raise production costs. The alternating arrangement of cells, required to avoid short circuits, complicates assembly and impedes effective thermal management. This leads to uneven heat distribution, localized overheating, and the risk of thermal runaway, worsening the difficulties faced by manufacturers.

[0005] At present, industry efforts mainly concentrate on tackling either electrical or thermal integration challenges separately. This fragmented approachoften results in trade-offs, such as diminished battery performance, higher production costs, and more complicated assembly processes. A comprehensive solution that simultaneously addresses both electrical and thermal integration challenges is notably lacking.

[0006] In light of these shortcomings, there is a critical necessity for an integrated solution that tackles both electrical and thermal integration challenges in cylindrical cell battery packs concurrently.

[0007] Relevant prior art provides helpful context for the current disclosure. For instance, US20230119524A1, named "Cooling System for Busbars," describes a busbar situated in a single plane without differentiation between positive and negative connections, achieving cooling through a gel -like substance on the busbar. Conversely, the present disclosure utilizes busbars positioned in two distinct planes and fills the entire area with a thermal interface material, significantly enhancing thermal management.

[0008] Another prior art, US10581055B2, titled "Busbar Module and Battery Pack, " indicates that both tabs are located on a single surface. The present disclosure diverges from this method by placing tabs on two separate surfaces, ensuring a unique configuration that improves both electrical and thermal integration.

[0009] Lastly, US20170229208A1, named "Multi-functional Busbar," refers to a busbar for connecting cells in parallel while maintaining a single cell orientation. While the present disclosure also preserves a uniform cell orientation, it additionally allows for series connections, a feature not explicitly covered in this prior art.

[0010] Thus, the current disclosure remedies the limitations of existing solutions by introducing a novel design for cylindrical cell battery packs that merges electrical and thermal management in a cohesive manner, thereby enhancing performance, reliability, and cost-effectiveness.OBJECTS OF THE INVENTION

[0011] The object of the disclosure is to provide a connecting rod for cylindrical cell battery packs that integrates both electrical connectivity and thermalmanagement into a single component, thereby reducing complexity and cost while enhancing performance.

[0012] Another object of the disclosure is to enable efficient electrical connectivity by utilizing dual busbars connected to the positive and negative terminals of the cells, allowing for series connections without the need to alternate cell orientations, thus simplifying assembly and improving reliability.

[0013] Yet another object of the disclosure is to enhance thermal conductivity by using the connecting rod as a thermal conduit, effectively transferring heat from the cells to a heat dissipation unit, such as a cold plate or heat sink, to maintain uniform temperature across the battery pack.

[0014] A further object of the disclosure is to incorporate thermal interface materials (TIMs) to fill voids between components, thereby minimizing thermal resistance and ensuring efficient heat transfer, which prevents localized overheating and maintains the thermal stability of the battery pack.

[0015] An additional object of the disclosure is to provide a flexible and modular design that can be customized for different cylindrical cell configurations and industrial applications, making it a versatile solution for various energy storage systems.

[0016] Another object of the disclosure is to improve reliability and safety by eliminating the need for alternating cell orientations, reducing potential short circuits, and simplifying maintenance by enabling individual cell replacement.

[0017] Yet another object of the disclosure is to offer a cost-effective solution by streamlining the electrical and thermal integration processes, reducing production costs, and eliminating the need for high-cost machinery for wire bonding.

[0018] A further object of the disclosure is to enhance the durability and longevity of the battery pack by preventing uneven current distribution and hotspots, thereby extending the life of the battery pack.

[0019] An additional object of the disclosure is to provide low-temperature adaptability by allowing the central connecting rod to function as a heating element, ensuring optimal battery performance in cold environments.

[0020] Finally, the object of the disclosure is to simplify the assembly process by maintaining a uniform cell orientation, which reduces manufacturing complexity and labor requirements, leading to faster production cycles and lower manufacturing costs.SUMMARY

[0021] This summary is provided to introduce concepts related to a system for integrated electrical and thermal busbar for battery packs having cylindrical cells. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in limiting the scope of the claimed subject matter.

[0022] The present disclosure discloses an integrated electrical and thermal busbar system for cylindrical cell battery packs, comprising a first busbar (1) configured to interface with positive terminals of a plurality of cylindrical cells (2) via resistance welding, a second busbar (3) configured to interface with negative terminals of the plurality of cylindrical cells (2) via resistance welding, and a central connecting rod (5) made from high-conductivity materials, including copper or aluminum, bridging the first busbar (1) and the second busbar (3) to provide electrical continuity and thermal management. The system further comprises a thermal interface material (TIM) (4) positioned to fill voids between the plurality of cylindrical cells (2), the central connecting rod (5), and a heat dissipation unit (7), all enclosed within a casing (6). The central connecting rod (5) serves dual functions of electrical connectivity and thermal management by transferring heat from the plurality of cylindrical cells (2) to the heat dissipation unit (7), which may be a cold plate or heat sink.

[0023] In accordance with the exemplary embodiment, the central connecting rod (5) provides external connections to act as a heating element in low-temperature conditions. This dual function simplifies the system design by reducing the number of components required, leading to potential cost savings in manufacturing and maintenance. By serving as a heating element in low-temperature conditions, the central connecting rod (5) ensures the system maintains optimal performance by preventing the adverse effects of cold environments on the system's operation.

[0024] In another exemplary aspect of the present disclosure, the central connecting rod (5) may be further configured to dampen vibration encountered by the battery pack or plurality of cells (2), by acting as an additional load path. Dampening of vibrations by the central connecting rod (5) may further provide mechanical stability to the battery pack. The additional mechanical stability specifically benefits in case of automotive or mobile application of battery packs that are subject to movement and shock.

[0025] Further, the thermal interface material (TIM) (4) enhances thermal conductivity by filling voids between the plurality of cylindrical cells (2), the central connecting rod (5), and the heat dissipation unit (7). This significantly improves thermal management by ensuring efficient heat transfer away from the cells, thereby maintaining optimal operating temperatures and enhancing performance. Filling the voids with TIM (4) can also dampen vibrations and provide additional mechanical stability to the battery pack, which can be particularly beneficial in mobile or automotive applications where the battery is subject to movement and shock.

[0026] In accordance with an aspect, the heat dissipation unit (7) is configured to effectively disperse heat. Incorporating a heat dissipation unit (7) in the form of a cold plate or heat sink effectively manages the thermal load by distributing and transferring excess heat away from critical components, thereby enhancing the system's reliability and longevity. The use of a cold plate or heat sink allows for active or passive cooling, leading to a more energy-efficient operation and potentially lower operational costs for different applications.

[0027] In accordance with an embodiment of the present disclosure, the plurality of cylindrical cells (2) are oriented in a single direction with cell tabs in a plane, allowing for series connection without alternating their positions. This configuration facilitates streamlined manufacturing processes and can lead to more compact and uniform battery pack designs, optimizing space utilization within the system. This configuration can improve the electrical connection quality between cells, resulting in lower internal resistance and potentially higher energy density and power output of the battery pack.

[0028] In accordance with an embodiment of the present disclosure, the system further comprises positive and negative terminals (8) facilitating current flow between the plurality of cylindrical cells (2) and external circuits. This ensures reliable and robust connections, simplifying manufacturing and assembly.

[0029] In accordance with an embodiment of the present disclosure, the casing (6) provides protection and structural integrity to the battery pack. This ensures that the entire assembly is protected from external factors, maintaining the integrity and performance of the battery pack over time.

[0030] A method for assembling an integrated electrical and thermal busbar system for cylindrical cell battery packs comprises integrating a central connecting rod (5) with dual functions of electrical connectivity and thermal management into the pack structure, filling voids with a thermal interface material (TIM) (4), attaching a heat dissipation unit (7) to the central connecting rod (5), and connecting external terminals of the central connecting rod (5) to function as a heating element in low-temperature conditions. This method streamlines the battery pack structure, which can improve reliability by reducing the number of components and potential failure points. The dual-function central connecting rod (5) can enhance the performance of the battery pack by ensuring consistent electrical connections while simultaneously managing the thermal load, leading to improved battery longevity and efficiency.BRIEF DESCRIPTION OF DRAWINGS

[0031] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

[0032] FIG. 1 illustrates an exploded view, in accordance with an exemplary embodiment of the present disclosure;

[0033] FIG. 2 illustrates an assembled view, in accordance with the present disclosure; and

[0034] FIG. 3 illustrates a method in accordance with an exemplary embodiment of the present disclosure.DETAILED DESCRIPTION

[0035] The present disclosure is subsequently described herein using various embodiments with reference to the accompanying drawing, wherein the reference numerals utilized in the accompanying drawing correspond to the similar elements throughout the description. While the present disclosure is illustratively described herein by way of example using embodiments and accompanying drawings, those skilled in the art will acknowledge that the disclosure is not limited to the described embodiments or drawings and is not intended to represent the scale of the different components.

[0036] Furthermore, certain components that may constitute a part of the disclosure might not be depicted in specific figures for the purpose of simplified illustration, and such omissions do not restrict the outlined embodiments in any manner. It should be comprehended that the drawings and the detailed description provided are not intended to limit the disclosure to the particular disclosed form, but instead, the disclosure is intended to encompass all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claim. Throughout this description, the term 'may' is used in a permissive sense, indicating the potential to, rather than in a mandatory sense, indicating a requirement.

[0037] Additionally, the words 'a' or 'an' signify at least one, and the word 'plurality' signifies 'one or more' unless otherwise specified. Moreover, the terminology and phraseology employed herein are solely for descriptive purposes and should not be construed as limiting in scope. Terms such as 'including', 'comprising', 'having', 'containing', or 'involving', and their variations, are intended to be broad and encompass the listed subj ect matter thereafter, as well as equivalents and additional subject matter not explicitly mentioned, and should not be interpreted as excluding other additives, components, integers, or steps. Similarly,the term 'comprising' is considered synonymous with the terms 'including' or 'containing' for applicable legal purposes.

[0038] The present disclosure relates to an integrated electrical and thermal busbar system specifically designed for cylindrical cell battery packs. This system introduces a connecting rod that performs dual functions: providing electrical connectivity and facilitating thermal management. The connecting rod is constructed from high-conductivity materials such as copper or aluminum, which are known for their excellent thermal and electrical properties. The system is designed to simplify the assembly process by enabling series connections without the need to alternate the orientation of the cells, thereby reducing complexity and improving reliability. The central connecting rod can also act as an additional load path to dampen vibrations and provide additional mechanical stability to the battery pack.

[0039] The disclosure comprises two busbars, each connected to the positive and negative terminals of the cylindrical cells. These busbars extend outward and connect to a central connecting rod, which serves as a bridge for electrical integration across the battery pack. This configuration ensures robust electrical connections while maintaining a uniform cell orientation, which is critical for efficient assembly and operation. Additionally, the connecting rod acts as a thermal conduit, transferring heat from the cells to a heat dissipation unit, such as a cold plate or heat sink. The inclusion of a thermal interface material (TIM) fills voids between components, enhancing thermal conductivity and ensuring uniform temperature distribution across the battery pack.

[0040] A key feature of the disclosure is its ability to function as a heating element in low-temperature conditions, thereby addressing performance issues in cold environments. The design allows for the connecting rod to provide external connections to an electric power source, which can be activated to maintain optimal battery temperatures. This dual-functionality not only improves the thermal stability of the battery pack but also enhances its overall performance and safety. The disclosure's modular and flexible design accommodates various cylindrical cellconfigurations, making it suitable for a wide range of applications, including automotive, consumer electronics, and large-scale energy storage systems.

[0041] This present disclosure is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description below:• First busbar (1)• Plurality of cylindrical cells (2)• Second busbar (3)• Thermal Interface Material (TIM) (4)• Central connecting rod (5)• Casing (6)• Heat Dissipation Unit (7)• Positive & Negative Terminals (8)

[0042] FIG 1 illustrates an exploded view of the integrated system for cylindrical cell battery packs, showcasing the arrangement and interaction of its components. The first busbar (1) and second busbar (3) are positioned to interface with the cylindrical cells (2) via resistance welding, ensuring efficient electrical connectivity. These busbars are identical in design, facilitating a balanced electrical connection across the battery pack. The central connecting rod (5) serves as a structural component, ensuring the alignment and stability of the busbars while also providing dual functions of electrical connectivity and thermal management.

[0043] The thermal interface material (4) is strategically placed to fill voids between the cells, busbars, and the heat dissipation unit (7). This material reduces thermal resistance and enhances overall thermal management by ensuring effective heat transfer. The casing (6) encloses the entire assembly, providing protection and structural integrity to the battery pack. The heat dissipation unit (7), which may be a cold plate or heat sink, disperses heat away from the cells, maintaining optimal operating temperatures and preventing overheating.

[0044] In one embodiment of the disclosure, the central connecting rod (5) is constructed from high-conductivity materials such as copper or aluminum. Thesematerials are selected fortheir excellent thermal and electrical properties, which are crucial for the dual functionality of the connecting rod. The rod not only facilitates electrical connectivity between the busbars but also acts as a thermal conduit, channeling heat away from the cells to the heat dissipation unit (7). This design ensures uniform temperature distribution across the battery pack, enhancing its performance and safety.

[0045] Additionally, the system may include external connections on the connecting rod (5) that allow it to function as a heating element in low-temperature conditions. This feature is particularly beneficial in cold environments, where maintaining optimal battery temperatures is critical for performance. By activating the heating element, the system can prevent the adverse effects of cold temperatures, ensuring reliable operation and extending the battery pack's lifespan.

[0046] In another embodiment, the thermal interface material (4) plays a vital role in enhancing thermal conductivity. By filling the voids between the cells, connecting rods, and heat dissipation units, the TIM minimizes thermal resistance and prevents hotspots. This ensures that all components are efficiently thermally connected, maintaining the thermal stability of the battery pack and improving its overall efficiency. The modular nature of the system allows for flexible configurations, making it adaptable to various cylindrical cell arrangements and industrial applications.

[0047] FIG. 2 illustrates an assembled view of the integrated system for cylindrical cell battery packs, highlighting the interaction and assembly of its components. The first busbar (1) and second busbar (3) are connected to the positive and negative terminals of the cells (2) through resistance welding, ensuring robust and reliable electrical connections. The central connecting rod (5) bridges these busbars, providing both electrical continuity and thermal conductivity. This configuration allows for efficient series connections without the need to alternate cell orientations, simplifying the assembly process.

[0048] The thermal interface material (4) is strategically placed to fill voids between the cells, connecting rods, and the heat dissipation unit (7). This material enhances thermal conductivity by minimizing thermal resistance, ensuring effectiveheat transfer from the cells to the heat dissipation unit. The heat dissipation unit, which may be a cold plate or heat sink, effectively disperses heat, maintaining uniform temperature across the battery pack and preventing localized overheating.

[0049] In one embodiment of the disclosure, the central connecting rod (5) is made from high-conductivity materials such as copper or aluminum, chosen for their superior thermal and electrical properties. This rod not only facilitates electrical connectivity but also acts as athermal conduit, channeling heat away from the cells to the heat dissipation unit (7). This dual functionality ensures uniform temperature distribution, enhancing the performance and safety of the battery pack.

[0050] Additionally, the system may incorporate external connections on the connecting rod (5) to function as a heating element in low-temperature conditions. This feature is particularly advantageous in cold environments, where maintaining optimal battery temperatures is crucial for performance. By activating the heating element, the system can mitigate the adverse effects of cold temperatures, ensuring reliable operation and extending the battery pack's lifespan.

[0051] In another embodiment, the thermal interface material (4) plays a critical role in enhancing thermal conductivity. By filling the voids between the cells, connecting rods, and heat dissipation units, the TIM minimizes thermal resistance and prevents hotspots. This ensures efficient thermal connectivity, maintaining the thermal stability of the battery pack and improving its overall efficiency. The modular nature of the system allows for flexible configurations, making it adaptable to various cylindrical cell arrangements and industrial applications.

[0052] The method for assembling the integrated electrical and thermal busbar system involves positioning the central connecting rod (5) within the battery pack to establish both electrical and thermal connectivity. The process includes attaching the first busbar (1) and second busbar (3) to the positive and negative terminals of the cylindrical cells (2) via resistance welding, ensuring robust electrical connections. The central connecting rod (5) bridges these busbars, facilitating seamless electrical integration across the battery pack. The thermal interface material (4) is applied to fill voids between the cells, connecting rods, and the heatdissipation unit (7), enhancing thermal conductivity and ensuring efficient heat transfer.

[0053] An embodiment of the present disclosure may include variations where the central connecting rod (5) is adapted to different shapes and sizes to accommodate various cylindrical cell configurations. The connecting rod may also be modified to include additional external connections, allowing it to function as a heating element in low-temperature conditions. This adaptability ensures that the system can be customized for specific applications, such as automotive or consumer electronics, where different thermal and electrical requirements may be present.

[0054] Another embodiment of the present disclosure may involve the use of alternative conductive materials for the central connecting rod (5), such as alloys or composites, to further optimize thermal and electrical performance. The thermal interface material (4) may also be selected from a range of materials with varying thermal conductivities to suit specific application needs, ensuring that the system remains versatile and adaptable.

[0055] Referring to FIG. 3 illustrates a method for assembling an integrated electrical and thermal busbar system designed for cylindrical cell battery packs. The assembly process commences at step 302 with the integration of a central connecting rod (5) engineered for optimal electrical conductivity and thermal management. This central rod is strategically positioned within the battery pack structure, allowing it to interface directly with the cylindrical cells. To further improve thermal management, any voids present within the battery assembly are filled with a specially formulated thermal interface material (4) at step 304. This material is selected for its high thermal conductivity properties, ensuring effective heat transfer away from the battery cells and reducing the risk of localized overheating.

[0056] In addition, at step 306 a heat dissipation unit (7) is affixed to the central connecting rod (5), enhancing the system's ability to expel heat generated during battery operation. The design of this heat dissipation unit includes features such as fins or other geometric shapes that maximize the surface area for heat dispersal, thereby improving the overall thermal efficiency of the battery pack.

[0057] The external terminals of the central connecting rod (5) are configured to function as heating elements during low-temperature conditions at step 308. This feature allows the battery pack to maintain operational efficiency even in adverse environments by providing supplemental heating when necessary, thereby supporting consistent performance across varying temperature ranges.

[0058] To ensure durability and reliability, a conformal coating is applied at step 310 over the central connecting rod (5) post-assembly. This coating serves as a protective barrier against environmental factors such as moisture, dust, and corrosive elements, significantly extending the operational lifespan of the busbar system.

[0059] Prior to full integration into the battery pack, a rigorous testing protocol at step 310 is implemented to verify the thermal and electrical continuity of the central connecting rod (5). This testing phase is critical in identifying and addressing any potential issues, ensuring that the integrated system maintains its intended functionality and safety standards.

[0060] Another exemplary embodiment of the present disclosure introduces an integrated electrical and thermal busbar system designed for cylindrical cell battery packs. This system features a first busbar (1) that connects to the positive terminals of multiple cylindrical cells (2) through resistance welding, along with a second busbar (3) that interfaces with the negative terminals of the same cells in a similar manner. A central connecting rod (5), crafted from high-conductivity materials such as copper or aluminum, bridges the first busbar (1) and the second busbar (3) to ensure both electrical continuity and effective thermal management throughout the system.

[0061] To enhance thermal performance, a thermal interface material (4) is strategically placed to fill the voids between the cylindrical cells (2), the central connecting rod (5), and a heat dissipation unit (7), which can be either a cold plate or a heat sink. Surrounding this assembly is a protective casing (6) that provides structural integrity. The central connecting rod (5) not only transfers heat from the cylindrical cells (2) to the heat dissipation unit (7) but also functions as a heating element during low-temperature conditions through its external connections.

[0062] The thermal interface material (4) plays a crucial role in boosting the system's thermal conductivity by efficiently filling gaps between the cylindrical cells (2), the central connecting rod (5), and the heat dissipation unit (7). The design of the heat dissipation unit (7) is focused on effectively dispersing heat generated during battery operation. Furthermore, the cylindrical cells (2) are arranged in a single direction with their cell tabs aligned in a plane, which simplifies the series connections without requiring alternating cell positions.

[0063] In addition to this, the system comprises positive and negative terminals (8) that facilitate current flow between the cylindrical cells (2) and external circuits. The busbars (1, 3) are specifically optimized to minimize resistive losses by shortening the paths for electrical current. To enhance heat transfer, the central connecting rod (5) may also incorporate embedded heat pipes, while vibrationdamping elements are placed between the cylindrical cells (2) and the central connecting rod (5) to promote improved mechanical stability.

[0064] For superior thermal performance, the thermal interface material (4) may incorporate phase-change material. Additionally, perforations in the busbars (1, 3) are designed to increase surface area and improve heat dissipation. The system is equipped with a monitoring unit that measures temperature and electrical parameters at the central connecting rod (5). Integrated cooling channels within the casing (6) further bolster the system's heat dissipation capabilities.

[0065] The central connecting rod (5) is modular, offering customization options for the battery pack's voltage and capacity. Moreover, both the thermal interface material (4) and the central connecting rod (5) provide mechanical cushioning to reduce stress on the cylindrical cells (2) during operation.

[0066] The assembly method for this integrated electrical and thermal busbar system involves several essential steps. Initially, the central connecting rod (5), which serves the dual purposes of electrical connectivity and thermal management, is integrated into the battery pack structure. Subsequently, voids within the pack are filled with thermal interface material (4), followed by the attachment of a heat dissipation unit (7) to the central connecting rod (5). The external terminals of thecentral connecting rod (5) are then connected to facilitate heating functionality in low-temperature conditions.

[0067] This assembly process further includes the application of a conformal coating over the central connecting rod (5) for environmental protection. The design of the heat dissipation unit (7) may accommodate either active or passive cooling methods. Before integrating into the battery pack, the system undergoes testing to ensure the thermal and electrical continuity of the central connecting rod (5) is intact.

[0068] The disclosure's benefits include enhanced thermal management through the use of high-conductivity materials and thermal interface materials, which prevent overheating and extend battery life. The dual-functionality of the connecting rod (5) improves electrical performance by maintaining reliable connections and reducing the need for complex wiring. The system's design reduces costs and weight by integrating thermal and electrical functions into a single component, while the external heating capability ensures optimal performance in cold environments. The simplified assembly process, with uniform cell orientation and series connection, streamlines manufacturing and enhances durability by minimizing mechanical stress and thermal cycling effects. These technical features collectively contribute to a more efficient, reliable, and cost-effective solution for cylindrical cell battery packs.

[0069] Further the advantages offered by this embodiment include enhanced thermal conductivity through the use of conductive materials in the connecting rod, improving overall battery performance. The design allows for attachable components, facilitating easier assembly and maintenance of the battery pack. The modular nature of the system enables flexible configurations, allowing for customization based on specific application requirements. The synergical integration of electrical connectivity and thermal management in the connecting rod optimizes space and efficiency within the battery pack. The versatile design accommodates various cell orientations and configurations, making it suitable for a wide range of battery applications.

[0070] The foregoing objects of the disclosure are accomplished, and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present disclosure described in the present embodiment. Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present disclosure may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present disclosure in virtually any appropriately detailed system, structure, or matter. The embodiments of the disclosure as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the scope of the disclosure.

Claims

WE CLAIM1. An integrated electrical and thermal busbar system for cylindrical cell battery packs, comprising:a first busbar (1) configured to interface with positive terminals of a plurality of cylindrical cells (2) via resistance welding;a second busbar (3) configured to interface with negative terminals of the plurality of cylindrical cells (2) via resistance welding;a central connecting rod (5) made from high-conductivity materials, including copper or aluminum, bridging the first busbar (1) and the second busbar (3) to provide electrical continuity and thermal management;a thermal interface material (4) positioned to fill voids between the plurality of cylindrical cells (2), the central connecting rod (5), and a heat dissipation unit (7); anda casing (6) enclosing the assembly;wherein the central connecting rod (5) serves dual functions of electrical connectivity and thermal management by transferring heat from the plurality of cylindrical cells (2) to the heat dissipation unit (7), which is either a cold plate or a heat sink.

2. The system of claim 1, wherein the central connecting rod (5) provides external connections to act as a heating element in low-temperature conditions.

3. The system of claim 1, wherein the thermal interface material (4) enhances thermal conductivity by filling voids between the plurality of cylindrical cells (2), the central connecting rod (5), and the heat dissipation unit (7).

4. The system of claim 1, wherein the heat dissipation unit (7) is configured to effectively disperse heat.

5. The system of claim 1, wherein the plurality of cylindrical cells (2) are oriented in a single direction with cell tabs in a plane, allowing for series connection without alternating their positions.

6. The system of claim 1, further comprising positive and negative terminals (8) facilitating current flow between the plurality of cylindrical cells (2) and external circuits.

7. The system of claim 1, wherein the casing (6) provides protection and structural integrity to the battery pack.

8. The system of claim 1, wherein the busbars (1, 3) are designed to optimize current path lengths, thereby minimizing resistive losses.

9. The system of claim 1, wherein the central connecting rod (5) is further configured to perform as embedded heat pipes for enhanced heat transfer.

10. The system of claim 1, further comprising vibration-damping elements between the cylindrical cells (2) and the central connecting rod (5) to improve mechanical stability.

11. The system of claim 1, wherein the thermal interface material (4) includes a phase-change material to enhance thermal performance.

12. The system of claim 1, wherein the busbars (1, 3) have perforations to increase surface area and improve heat dissipation.

13. The system of claim 1, further comprising a monitoring unit to measure temperature and electrical parameters at the central connecting rod (5).

14. The system of claim 1, wherein the casing (6) includes integrated cooling channels to enhance heat dissipation.

15. The system of claim 1, wherein the central connecting rod (5) is modular, allowing for customization of the battery pack's voltage and capacity.

16. The system of claim 1, wherein the thermal interface material (4) and central connecting rod (5) also provides mechanical cushioning to reduce stress on the cylindrical cells (2) during operation.

17. A method for assembling an integrated electrical and thermal busbar system for cylindrical cell battery packs, comprising:integrating (302) a central connecting rod (5) with dual functions of electrical connectivity and thermal management into the pack structure; filling (304) voids with a thermal interface material (4); attaching (306) a heat dissipation unit (7) to the central connecting rod (5); andconnecting (308) external terminals of the central connecting rod (5) to function as a heating element in low-temperature conditions.

18. The method of claim 17, further comprising the step of applying (310) a conformal coating over the central connecting rod (5) for environmental protection.

19. The method of claim 17, wherein the heat dissipation unit (7) is a cold plate or heat sink configured to actively or passively cool the system.

20. The method of claim 17, further comprising the step (312) of testing the thermal and electrical continuity of the central connecting rod (5) before integrating it into the system.Dated this 15thof January 2025Samendra Patil IN / PA 5092 Agent for the Applicant

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