Battery Pack Cooling Element for Busbar and Hotspot Heat Transfer
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Solution Overview
Problem
The operational life of rechargeable battery cells is significantly influenced by temperature, and existing thermal management systems are inadequate in maintaining optimal temperatures, leading to uneven aging and reduced cycle life.
Innovation Solution
A battery pack thermal management system featuring a cooling element with heat exchange surfaces in contact with battery cell busbars and electrical circuit components, utilizing thermal transfer channels and interface materials to efficiently conduct heat away from hotspots and terminals, while also serving as a fixing element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional thermal management systems are used, then basic cooling function is provided, but operational life of battery cells is reduced and temperature control is insufficient
Solution Approach 1:
The cooling element is merged with the battery pack structure to integrate thermal management functions. The cooling element includes a first heat exchange surface in thermal contact with battery cell busbars and hotspot areas, and a second heat exchange surface in thermal contact with electrical circuit components, consolidating multiple cooling functions into a single integrated component that extends operational life while maintaining temperature control.
2Duration of action of moving object
If thermal management is improved, then operational life extends, but device complexity increases
Solution Approach 1:
The cooling element integrates multiple thermal management functions into a single component structure, combining cooling of battery cells, busbars, and electrical circuit components without requiring separate systems for each, thereby extending operational life while minimizing added complexity.
Solution Approach 2:
The cooling element serves multiple purposes simultaneously: it cools battery cells through the first heat exchange surface, cools electrical circuit components through the second heat exchange surface, and provides structural support within the battery pack, reducing the need for additional separate components.
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 system extends the operational life of battery cells, increases the number of usable charge cycles, and allows for faster charging and discharging while maintaining cells near optimal temperature, optimizing thermal management and material usage.
Implementation Method 1
thermal energy may be configured to be conducted from the at least one battery cell busbar, heat producing hotspot area of the battery cells, and at least one electrical circuit component to the cooling element
Data Source
Figure 1~3
Figure 2~4
AI summary
A system for battery pack thermal management, wherein the battery pack comprising a cell stack comprising battery cells arranged in the cell stack, wherein the system comprising a cooling element arranged on a top face of the battery cells and comprising a first heat exchange surface and second heat exchange surface, wherein the cooling element comprising at least one extension arranged on the first exchange surface; the first heat exchange surface is configured to be in thermal contact with battery cell busbars and heat producing hotspot areas of a battery cell casing, the second heat exchange surface is configured to be in thermal contact with electrical circuit components of the battery pack, and thermal energy is configured to be conducted from the battery cell busbars, heat producing hotspot areas, and electrical circuit components to the cooling element. Also a battery pack and a method are disclosed.