EV Battery Busbar Housing for Indirect Thermal Coupling
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Solution Overview
Problem
Existing battery systems for electric vehicles do not effectively cool busbars, leading to increased heat input into battery cells, which accelerates aging and can damage electrical insulation, while separate cooling systems for busbars are costly and inefficient.
Innovation Solution
A busbar housing is thermally coupled to the battery module housing, indirectly cooling the busbars via the existing cell cooling system, allowing for a longer cooling path and controlled temperature range without overcooling the cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the existing battery cell cooling system is used to cool the busbars directly, then the busbars are cooled, but the battery cells are overcooled or the cooling system requires unnecessarily high power consumption
Solution Approach 1:
The patent introduces a busbar housing as an intermediary component between the battery cells and the busbars. The housing is thermally coupled to both the battery module housing (which is cooled by the cooling system) and the busbars. This intermediary structure allows heat to be transferred from the busbars to the cooling system indirectly, enabling independent temperature control of busbars and battery cells without requiring the cooling system to operate at high power consumption levels
2Temperature
If the busbars are cooled to the same temperature as the battery cells, then the busbars are adequately cooled, but the battery cells are overcooled reducing system efficiency
Solution Approach 1:
The patent applies local quality by creating different thermal zones within the cooling system. The busbar housing is thermally coupled to the battery module housing in such a way that the busbars operate at a higher temperature range (e.g., 60-150°C) while the battery cells are maintained at their optimal lower temperature range (e.g., 20-40°C). This localized thermal management allows each component to operate in its optimal temperature range, improving overall system efficiency
3Device complexity
If no separate cooling system is provided for busbars, then the system remains simple and cost-effective, but the busbars overheat causing accelerated aging of battery cells and potential damage to electrical insulation
Solution Approach 1:
The patent makes the existing cooling system multi-functional by enabling it to cool both the battery cells and the busbars through the busbar housing intermediary. The same cooling circuit that cools the battery cells also cools the busbars indirectly through thermal coupling with the busbar housing. This eliminates the need for a separate cooling system while providing adequate cooling for both components, maintaining system simplicity and cost-effectiveness while improving reliability
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 efficiently cools busbars to a higher temperature range than cells, reducing thermal losses and extending cell life with minimal impact on cell cooling efficiency and cost.
Implementation Method 1
the busbar housing is thermally coupled at least in portions to at least one of the battery modules
Implementation Method 2
the busbars are cooled via the cooling system for cooling the battery cells via a fairly long cooling path
Data Source
AI summary
A battery system for an electrically or semi-electrically driven vehicle, in particular for a passenger car. The battery system includes at least two battery modules, each having a module housing and a plurality of battery cells arranged in the module housing. The battery system includes a cooling system for cooling the battery cells. The battery system includes a busbar, wherein the at least two battery modules are connected to one another by the busbar. The battery system includes a busbar housing configured outside of the module housing, wherein the busbar is arranged in the busbar housing and is thermally coupled to the busbar housing. The busbar housing is thermally coupled, at least in portions, to at least one of the battery modules, preferably to the module housing of the at least one battery module.