Backplane Assembly with Integrated Power and Cooling Substructures
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Solution Overview
Problem
Current battery racks face challenges such as complex and labor-intensive installation and servicing due to exposed cables, potential for mechanical damage and coolant leaks, and the risk of thermal runaway in lithium-ion batteries, which can lead to unsafe conditions and equipment damage.
Innovation Solution
A backplane assembly with integrated power, cooling, and exhaust substructures that allows for blind mate connections and automatic formation of power and optical interfaces, eliminates the need for external cables and hoses, and includes a venting system to safely direct gases away from the battery rack, while optimizing cooling and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external flexible hoses and cables are used to connect battery modules to the rack system, then power and coolant connections can be established, but installation and servicing become difficult and labor-intensive
Solution Approach 1:
The patent integrates power connectors and coolant connectors into a single unified connector assembly that engages with the battery module as one unit. This merging of previously separate connection operations into a single integrated connector eliminates the need for separate cable routing and hose connection steps, thereby maintaining connection reliability while dramatically simplifying installation and servicing operations.
Solution Approach 2:
The rack-mounted connector assembly serves multiple functions simultaneously: it provides both power electrical connections and coolant fluid connections through a single integrated structure. This multi-functionality eliminates the need for separate external cables and hoses, reducing installation complexity while ensuring reliable connections for both power and cooling systems.
2Ease of operation
If external cables are exposed on the front face of the rack, then power connections can be made to battery modules, but the cables are subject to impact and mechanical damage
Solution Approach 1:
The patent extracts the vulnerable external cable routing from the front face of the rack and relocates all connector interfaces to the rear of the battery module. By removing the exposed cabling from the front face where it is susceptible to impact and mechanical damage, the design maintains ease of operation through rear-access connectors while eliminating the mechanical damage risk associated with exposed front-face cables.
3Adaptability or versatility
If multiple cable lengths are used to accommodate various physical arrangements of battery modules, then all modules can be connected, but the power circuits become complex and excessively long
Solution Approach 1:
The patent employs flexible busbars with adjustable geometry that can be configured to match different battery module arrangements. Instead of using multiple fixed-length cables that create complex routing, the flexible busbars can be dynamically shaped to follow optimal paths, reducing circuit complexity while maintaining adaptability to various physical configurations of battery modules.
4Ease of operation
If the backplane assembly includes integrated power and cooling substructures, then installation is simplified and connections are automatic, but the manufacturing complexity increases
Solution Approach 1:
The backplane assembly is segmented into modular components including separate power connector modules, coolant connector modules, and mounting structures. This segmentation allows each sub-assembly to be manufactured and tested independently using standardized processes, then integrated into the complete backplane assembly. The modular approach simplifies manufacturing by breaking down the complex integrated structure into manageable, repeatable production steps.
Data Source
Figure 1
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Figure 3A~3B
AI summary
There is provided a backplane assembly with a power substructure and a cooling substructure. Battery modules may be engaged with the backplane assembly. When engaged, power connectors in the power substructure engage with corresponding power connectors on the battery modules. A cooling fluid moving through the cooling substructure is directed toward the battery modules so as to cool the battery modules during operation. The backplane assembly may additionally include an exhaust substructure. Gases vented by the battery modules move through the exhaust substructure and are directed away from the backplane assembly.