Battery Cell Cooling Using Busbar Terminal Tab Flow Diversion
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Solution Overview
Problem
Battery cells in electric or hybrid vehicles often experience reduced performance and shortened lifespan due to overheating, which can occur in localized areas within the battery module where coolant flow is inadequate, leading to inefficient cooling and potential failure.
Innovation Solution
A method of cooling battery cells within a housing chamber by diverting coolant flow using terminal tabs on the busbar, which are angled to impinge upon the coolant flow, ensuring even distribution and minimizing material usage and weight by utilizing existing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cell trays with coolant circulation are used, then cooling is provided to battery cells, but dead spots form with poor coolant circulation leading to localized overheating
Solution Approach 1:
The terminal tab structure itself serves dual purposes: electrical connection and coolant flow diversion. The tab's geometric features (protrusions, angles, positioning) automatically redirect coolant flow to dead spots without requiring separate flow control components, enabling the system to self-correct circulation deficiencies
Solution Approach 2:
The terminal tab is designed to perform multiple functions simultaneously: providing electrical connection between cells and external circuitry, and acting as a flow diversion element to redirect coolant to regions with poor circulation. This multi-functionality eliminates the need for additional dedicated flow control parts
2Temperature
If additional components are added to divert coolant flow, then cooling distribution is improved, but material usage and weight increase
Solution Approach 1:
The terminal tab is designed to perform multiple functions simultaneously: providing electrical connection between cells and external circuitry, and acting as a flow diversion element to redirect coolant to regions with poor circulation. This multi-functionality eliminates the need for additional dedicated flow control parts
Solution Approach 2:
The patent merges the electrical connection function and coolant flow control function into a single integrated component (the terminal tab). By combining these functions, the design eliminates separate flow diversion components, reducing overall part count and material usage while achieving improved coolant distribution
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 method enhances cooling efficiency, maintaining battery cells within optimal temperature ranges, reducing the risk of overheating and extending the operational life of the cells while minimizing material usage and weight.
Implementation Method 1
diverting at least a part of the coolant flow from its inlet flow path due to impingement of the flow upon part of the terminal tab
Implementation Method 2
coolant fluid to circulate around parts of the battery cells, thereby providing a cooling effect to the cells as heat is transferred from the cells to the coolant
Data Source
AI summary
A method of cooling an array of battery cells within a chamber in a housing, the battery cells being electrically connected via a busbar having at least one terminal tab for connection to an electrical terminal in the housing, the method comprising the steps of: supplying coolant through an opening in the housing into the chamber; and diverting at least a part of the coolant flow from its inlet flow path due to impingement of the flow upon part of the terminal tab.