Traction Battery Assembly Thermal Plate and Busbar Integration
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Solution Overview
Problem
Current traction battery assemblies for motor vehicles face challenges in efficiently managing thermal regulation and electrical connectivity between battery cell arrays, which can lead to suboptimal performance and potential short circuits due to inadequate thermal management and busbar configurations.
Innovation Solution
The proposed traction battery assembly features first and second arrays with cells arranged such that their terminal sides face each other, with a thermal plate in contact for thermal management and busbars for mechanical and electrical coupling, ensuring efficient thermal regulation and electrical connectivity while preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal plate is disposed between arrays with terminal sides facing each other, then thermal management is improved, but device complexity increases
Solution Approach 1:
The thermal plate is integrated into the battery assembly structure itself, merging the thermal management function with the structural framework. This combination allows heat dissipation without adding separate, complex thermal management systems, thus improving temperature control while minimizing increases in device complexity.
Solution Approach 2:
The thermal plate serves multiple functions: it provides thermal management by contacting terminal sides for heat dissipation, while also serving as part of the structural support framework of the battery assembly. This multi-functionality improves thermal management efficiency without proportionally increasing device complexity.
2Reliability
If busbar mechanically and electrically connects terminals of cells in first and second arrays, then electrical connectivity is improved, but device complexity increases
Solution Approach 1:
The busbar is integrated into the overall battery assembly structure, merging electrical connection functions with structural elements. This integration ensures reliable mechanical and electrical connectivity between cell terminals while avoiding the need for separate, complex connection systems.
Solution Approach 2:
The busbar configuration is designed to segment and connect specific cell terminals in a systematic pattern, providing reliable electrical connectivity between first and second arrays. This segmented approach ensures proper electrical connections while maintaining organizational simplicity and reducing overall device complexity.
3Temperature
If cells are arranged with terminal sides facing each other, then thermal management efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The battery assembly employs asymmetric array arrangements where first and second arrays are positioned with terminal sides facing each other. This asymmetric configuration optimizes thermal management efficiency by enabling direct thermal contact through the thermal plate, while the design accommodates manufacturing tolerances through the overall structural framework.
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
This configuration enhances thermal management and electrical connectivity, improving the performance and safety of traction battery assemblies by maintaining optimal temperatures and ensuring reliable electrical connections between cells.
Implementation Method 1
A thermal plate is disposed between the arrays and is in contact with the terminal sides
Implementation Method 2
A busbar mechanically and electrically connects a terminal of a cell in the first array to a terminal of a cell in the second array
Data Source
AI summary
A traction battery assembly includes first and second arrays each having cells with terminals on a terminal side of the array. The arrays are arranged with the terminal sides facing each other. A thermal plate is disposed between the arrays and is in contact with the terminal sides. A busbar mechanically and electrically connects a terminal of a cell in the first array to a terminal of a cell in the second array.