Battery Backplane with Integrated Bus Bar and Thermal Conduits
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Solution Overview
Problem
High-voltage battery packs generate substantial heat during operation, degrading efficiency and structural integrity, and existing thermal management systems are complex and require access to high-voltage bus connections, posing safety risks during assembly and service.
Innovation Solution
A backplane assembly that integrates bus bar electrical connections with a thermal regulation structure, using internal conduits for heat transfer fluid to directly cool or heat bus bar assemblies, eliminating the need for threaded fasteners and providing a 'finger-proof' interface, reducing bus bar size and surface area for heat radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermal management systems are used with separate cooling plates and fluid circulation, then thermal regulation is achieved, but device complexity increases and safety risks arise during assembly due to access to high-voltage bus connections
Solution Approach 1:
The patent combines the thermal management function with the electrical backplane structure by integrating cooling channels directly into the backplane body. The backplane serves dual purposes: electrical connection via bus bars and thermal regulation via embedded cooling channels, eliminating the need for separate cooling plates and reducing overall system complexity.
Solution Approach 2:
The backplane assembly is designed to perform multiple functions simultaneously: it provides electrical connections through integrated bus bars, structural support for battery modules, and thermal management through embedded cooling channels. This multi-functional design reduces the number of separate components needed in the system.
2Temperature
If larger bus bar surface area is used for heat radiation, then thermal management improves, but device volume and weight increase
Solution Approach 1:
The patent uses fluid circulation through embedded cooling channels within the bus bars to transfer heat away from the electrical connections. This hydraulic cooling system allows for effective heat dissipation without requiring large surface area bus bars, maintaining compact dimensions while managing thermal loads.
3Strength
If threaded fasteners and joining structures are used for backplane-to-battery module connection, then mechanical strength is achieved, but ease of operation deteriorates due to required access to high-voltage bus
Solution Approach 1:
The electrical connection and mechanical attachment functions are merged into a single integrated backplane assembly. The bus bars are embedded within the backplane structure, allowing electrical connections to be made without exposing operators to high-voltage components during the mechanical attachment process, thereby improving safety and ease of operation.
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 backplane assembly effectively manages thermal regulation within the battery pack, enhancing safety and reducing bus bar size while maintaining efficient heat transfer, thus improving the overall performance and reliability of the battery pack.
Implementation Method 1
heat transfer fluid is circulated to and from fins interspaced between the battery cells
Implementation Method 2
The internal conduits extend along a length of the elongated backplane body adjacent to the bus bar assemblies such that the heat transfer fluid is conducted to and from the bus bar assemblies via the internal conduits
Implementation Method 3
the generated heat degrades the efficiency and overall structural integrity of the battery pack. Thermal management systems are therefore used to closely regulate the temperature of the battery pack
Data Source
AI summary
A battery pack for use with a supply of heat transfer fluid includes a plurality of battery modules arranged in one or more rows, and an elongated backplane positioned between the rows or adjacent to one row. The backplane has external longitudinal surfaces, and includes multiple bus bar assemblies equal in number to the number of battery modules and connected to the external longitudinal surfaces. The elongated backplane defines internal conduits configured to receive heat transfer fluid from the supply and extending along a length of the backplane adjacent to the bus bar assemblies. End plates of the battery modules include negative and positive voltage terminals mating with corresponding electrical connectors of a respective one of the bus bar assemblies. An electrical connection between each bus bar assembly and corresponding voltage terminals is established via a push-to-connect operation, with a finger-proof barrier covering the positive terminal.