Battery Module Bus Bar Topology for Thermal Management
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Solution Overview
Problem
Conventional battery modules with stacked lithium-ion battery cells require long bus bars for connection, which generate heat and are often spaced away from cooling sources, inefficiently managing thermal issues.
Innovation Solution
A battery module design where battery cells are arranged in a stacked configuration with terminals oriented in various positions, allowing direct electrical communication between non-adjacent cells, reducing the length and count of bus bars and optimizing thermal management by localizing bus bars near cooling sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are connected in series with conventional stacked configuration, then electrical connection is established, but bus bar length increases and heat generation increases
Solution Approach 1:
The patent transitions from a conventional linear stacked configuration to a three-dimensional arrangement where battery cells are positioned at corners of a rectangular prism. This spatial reorganization allows electrical connections to be made in multiple dimensions, reducing the required bus bar length while maintaining series connection reliability.
Solution Approach 2:
The patent implements a compact modular structure where battery cells are nested within a rectangular prism framework. This nesting approach allows efficient space utilization and minimizes the distance between connected cells, thereby reducing bus bar length and associated heat generation.
2Reliability
If bus bars are spaced from cooling sources, then electrical connection is maintained, but thermal management efficiency decreases
Solution Approach 1:
The patent positions bus bars in close proximity to cooling sources by utilizing the three-dimensional cell arrangement. This localized optimization allows different parts of the battery module to have different thermal management characteristics, with bus bars strategically positioned where cooling is most effective while maintaining electrical connection reliability.
3Object-generated harmful factors
If bus bar length is reduced, then heat generation decreases, but electrical connection complexity increases
Solution Approach 1:
The patent divides the battery module into modular units with standardized corner-positioned cells. This segmentation creates repeating connection patterns that, while three-dimensional, follow predictable topologies. The modular approach reduces overall complexity by allowing standardized connection modules to be replicated rather than designing unique connections for each cell.
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 minimizes bus bar length, reduces heat generation during charging and discharging, and enhances thermal management by strategically positioning bus bars for improved cooling, leading to a more efficient and compact battery module.
Implementation Method 1
A battery cell has been proposed as a clean, efficient and environmentally responsible power source for electric vehicles and various other applications. One type of battery cell is known as the lithium-ion battery. The lithium-ion battery is rechargeable
Implementation Method 2
The bus bars 8 consistently generate heat during charging/discharging
Data Source
AI summary
A battery module comprising a plurality of battery cells arranged in a stacked configuration, each of the battery cells including a first terminal disposed on a first end of the battery cell and a second terminal disposed on a second end of the battery cell, wherein the first terminal of at least one of the battery cells is in direct electrical communication with the second terminal of another non-adjacent one of the battery cells.