Integrated Battery Frame with Buss Bars and Cooling Channels
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Solution Overview
Problem
The complexity and cost of assembling and maintaining lithium battery systems in hybrid electric vehicles are increased by the large number of parts and the separate battery management system, which can lead to electrical noise interference and reduced usability due to thermal management challenges.
Innovation Solution
A battery system with a frame that secures lithium-ion cells and facilitates cooling fluid flow, integrated with a battery management system and connectors to reduce parts and wire length, allowing for efficient electrical current flow and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large number of buss bars and connectors are used to connect individual battery cells, then electrical connectivity is achieved, but assembly complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple buss bars into a single integrated buss bar structure that provides electrical connectivity for multiple battery cells simultaneously. This merging approach reduces the total number of connectors and simplifies assembly while maintaining reliable electrical connections across all cells.
Solution Approach 2:
The integrated buss bar design serves multiple functions: it provides electrical connectivity, structural support, and thermal management pathways for multiple battery cells. This multi-functionality reduces the need for separate components and simplifies the overall battery pack architecture.
2Reliability
If a separate battery management system is used, then battery monitoring is achieved, but wire length increases and electrical noise interference occurs
Solution Approach 1:
The battery management system is integrated directly into the battery pack structure, combining monitoring functions with the physical battery assembly. This integration eliminates long external wiring connections, reducing electrical noise interference and simplifying the overall system architecture.
3Reliability
If traditional battery packaging is used, then battery cells are contained, but thermal management becomes difficult and cooling requirements are not met
Solution Approach 1:
The patent incorporates cooling channels and fluid flow pathways within the battery pack structure, using hydraulic principles to circulate coolant through strategic locations. This enables effective thermal management while maintaining compact packaging and proper battery cell containment.
4Reliability
If many individual parts are used for assembly, then battery system functionality is achieved, but manufacturing and maintenance costs increase
Solution Approach 1:
The patent merges multiple discrete components into integrated assemblies, such as combining buss bars with structural supports and integrating the battery management system into the pack housing. This reduction in part count lowers manufacturing complexity and maintenance costs while preserving all necessary battery system functions.
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
The solution simplifies assembly, reduces material usage, and enhances thermal management by integrating the battery management system with the battery system, minimizing electrical noise and improving overall performance and maintainability.
Implementation Method 1
features for spacing apart the plurality of cells to facilitate the flow of a cooling fluid between the cells
Data Source
AI summary
A battery system includes a plurality of electrochemical cells each having at least one terminal and a plurality of members coupled together to form a frame for securing the electrochemical cells in place. At least one of the members has openings configured to receive the terminals of the plurality of cells and also has features for spacing apart the plurality of cells to facilitate the flow of a cooling fluid between the cells. The battery system further includes a battery management system provided at a first end of the frame and a device provided at a second end of the frame for providing the cooling fluid to the cells and to the battery management system simultaneously.