Integrated Battery Power Bus Substrate for Lighter Pack Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs are mass- and volume-inefficient due to separate power buses and numerous wire/bus bar connections, leading to increased cost, complexity, and safety issues, as well as inefficiencies in heat management.
Innovation Solution
Integration of a power bus with the battery management system (BMS) unit directly into a substrate, eliminating the need for wires and bus bar connections, and using thermally conductive materials for improved heat transfer and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If separate power buses and wire/bus bar connections are used in conventional battery packs, then power transfer function is achieved, but mass efficiency deteriorates and volume efficiency deteriorates
Solution Approach 1:
The patent merges the power bus with the substrate (PCB) into a single integrated structure. The power bus is formed as conductive traces directly on the substrate, eliminating the need for separate power bus components and their connections. This integration directly reduces the overall mass and volume of the battery pack while maintaining the power transfer function.
Solution Approach 2:
The invention extracts and eliminates the separate wire and bus bar connection elements from the conventional battery pack structure. By removing these discrete components and replacing them with integrated substrate-based power buses, the patent reduces the number of connection points and associated hardware, thereby reducing mass and simplifying the overall structure.
2Ease of manufacture
If numerous wire/bus bar connections are used in conventional battery packs, then power transfer is achieved, but manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The power bus and substrate are merged into a single manufactured component. The conductive traces are formed directly on the substrate during substrate manufacturing processes, eliminating the need for separate wire routing, bus bar attachment, and connection assembly steps. This integration significantly reduces manufacturing complexity and associated costs.
Solution Approach 2:
The patent replaces the mechanical connection system (wires, bus bars, connectors, and their physical assemblies) with an integrated electrical trace system on the substrate. This substitution eliminates complex mechanical assembly operations and reduces manufacturing steps, thereby lowering production costs and simplifying the manufacturing process.
3Reliability
If numerous wire/bus bar connections are used in conventional battery packs, then power transfer is achieved, but safety deteriorates due to increased connection points
Solution Approach 1:
The invention extracts and removes the numerous discrete connection points (wire connections, bus bar attachments) from the conventional battery pack design. By replacing these multiple potential failure points with an integrated substrate-based power bus system, the patent reduces the number of connection interfaces, thereby improving safety and reliability.
4Temperature
If separate power buses are used in conventional battery packs, then power transfer function is achieved, but thermal management efficiency deteriorates
Solution Approach 1:
The power bus and thermal management functions are merged into the substrate structure. The substrate serves dual purposes: electrical power transfer through conductive traces and thermal management through its thermally conductive properties. This integration eliminates the need for separate thermal management components and simplifies the overall structure while improving heat transfer efficiency.
Solution Approach 2:
The substrate is designed to perform multiple functions simultaneously: it provides structural support, electrical power transfer through integrated power buses, and thermal management through heat conduction. This multi-functionality reduces the need for separate dedicated components for each function, thereby simplifying the thermal management structure while improving efficiency.
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 approach results in a more efficient, safer, and cost-effective battery pack with reduced connection points, improved assembly speed, and enhanced thermal performance, making it suitable for applications like aerial vehicles.
Implementation Method 1
a substrate directly connected to the at least one electrochemical cell and configured to transfer heat, power, and signals between the substrate and the at least one electrochemical cell
Implementation Method 2
a substrate directly connected to the at least one electrochemical cell and configured to transfer heat, power, and signals between the substrate and the at least one electrochemical cell
Data Source
AI summary
A battery pack comprising a substrate comprising a battery power bus integrated into the substrate; and a pack controller; and at least one electrochemical cell connected directly to the substrate. A printed circuit board comprising a power bus integrated into the printed circuit board, wherein the power bus is connected to and configured to transfer power to and/or from at least one electrochemical cell; and at least one controller configured to control the at least one electrochemical cell. A thermal management system comprising at least one electrochemical cell; and a substrate directly connected to the at least one electrochemical cell and configured to transfer heat, power, and signals between the substrate and the at least one electrochemical cell. A thermal management method. A method of assembling a battery pack, comprising attaching at least one electrochemical cell of the battery pack directly to a substrate at least in part by welding.