Battery Pack Conductor Segmentation for Thermal and Electrical Optimization
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Solution Overview
Problem
Existing battery pack designs face challenges in achieving high-current-resistant electrical connections and effective heat dissipation, particularly in battery packs for electric vehicles, where high peak currents and temperature management are critical.
Innovation Solution
The solution involves dividing the conductor into a heat-transferring surface section and an electrical contact section, allowing for optimized heat transfer and high-current-resistant connections. These sections are mechanically fastened to a temperature control element, with the heat-transferring section pressed against it via a pressure piece and the electrical contact sections connected either via a contact bridge or directly, using methods like laser soldering or welding for a strong, integral connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductor is designed as a single integrated component, then the structure is simple and manufacturing is easier, but it cannot simultaneously optimize both heat transfer area and electrical contact area
Solution Approach 1:
The conductor is divided into two distinct sections: a heat-transferring surface section with optimized thermal contact area and an electrical contact section with optimized electrical connection properties. This segmentation allows each section to be independently optimized for its specific function, resolving the contradiction between manufacturing simplicity and functional optimization.
Solution Approach 2:
Different sections of the conductor are given different geometric and material properties suited to their specific functions. The heat-transferring surface section has properties optimized for thermal contact, while the electrical contact section has properties optimized for electrical connection, allowing local optimization without compromising overall manufacturability.
2Temperature
If the conductor is pressed against the temperature control element with high force, then heat transfer is improved, but the mechanical strength of the electrical connection may be compromised
Solution Approach 1:
By separating the heat-transferring surface section from the electrical contact section, the mechanical load from pressing force is isolated to the heat transfer interface, while the electrical connection maintains its own mechanical integrity through separate attachment to the temperature control element.
Solution Approach 2:
The temperature control element acts as an intermediary structure that independently supports both the heat-transferring surface section and the electrical contact section, allowing optimized pressing force for heat transfer without compromising electrical connection strength.
3Strength
If welding is used to attach the conductor to the temperature control element, then electrical connection and mechanical strength are improved, but heat transfer contact may be compromised due to welding material interference
Solution Approach 1:
The attachment process is segmented into separate welding operations: one for the electrical contact section and another for the heat-transferring surface section. This allows welding to be applied where needed for strength and electrical connection, while the heat transfer interface can be optimized for direct thermal contact.
Solution Approach 2:
Welding is applied locally at the electrical contact section where mechanical strength and electrical connection are priorities, while the heat-transferring surface section maintains direct contact with the temperature control element without welding material interference, preserving heat transfer quality.
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 design enables reliable high-current resistance and efficient heat dissipation, preventing damage from high currents and temperature fluctuations, while allowing for automated welding and enhanced thermal conductivity.
Implementation Method 1
the heat-transferring surface section of the arrester is pressed against the tempering element in a heat-transferring connection
Implementation Method 2
the contact section of one arrester is electrically connected to the contact section of the other arrester
Implementation Method 3
a laser liquefying the solder introduced between the overlapping conductors
Implementation Method 4
The mechanical attachment can be produced by an integral connection. This integral connection is preferably produced by laser soldering
Implementation Method 5
the attachment of the arresters to the hollow profile is exclusively determined by the welding
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a battery pack consisting of a plurality of individual flat battery cells (6), each having a cathode arrester (17) and an anode arrester (18). Two arresters (17, 18) of adjacent battery cells (5, 6) are electrically connected to each other. According to the invention, the arresters (17, 18) are in contact with a thermally conductive temperature control element (30), the surface of the arrester (17, 18) being divided into a first, heat-transferring surface section (45) and a second, electrical contact section (46). The heat-transferring surface section (45) is pressed against the temperature control element (30) via a pressure piece (25) in a heat-transferring connection, and the contact section (46) of one arrester (17) is electrically connected to the contact section (46) of the other arrester (18).