Battery Module Thermal Coupling Power Electronics

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Solution Overview

Problem

Conventional battery systems for electric vehicles face challenges in managing heat generated by both battery cells and power electronics, leading to increased cooling system costs, space requirements, and weight, particularly due to the additional heat source from power electronics.

Innovation Solution

A battery module design that thermally couples power electronics to battery cells using a heat-conducting element with a comb-shaped profile, distributing heat from the electronics over a large area of the cells, thereby reducing the need for extensive cooling system enhancements and minimizing additional weight and installation space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If power electronics are integrated into the battery module, then functional versatility is improved, but heat generation increases requiring enhanced cooling

Engineering Contradiction:

Improvefunctional integrationVSAvoidheat generation

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The power electronics are integrated directly into the battery module structure, merging two previously separate systems (battery and power electronics) into a single modular unit. This reduces overall system complexity and allows for optimized thermal management by treating the heat from both sources as a unified thermal load that can be managed through the existing battery cooling system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent converts the harmful heat generated by power electronics into a beneficial thermal resource by directing it toward battery cells that require thermal management. The heat from electronics is transferred through thermally conductive elements to adjacent battery cells, utilizing the temperature differential to reduce the cooling burden on the battery system.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Temperature

If a separate cooling system for power electronics is implemented, then thermal management effectiveness is improved, but device complexity and cost increase

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The battery cooling system is designed to serve dual functions: cooling the battery cells during normal operation and cooling the integrated power electronics during operation. This multi-functionality eliminates the need for a separate cooling system for electronics, reducing overall system complexity while maintaining effective thermal management for both components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-generated harmful factors

If extensive cooling system enhancements are made, then thermal management capability is improved, but weight and installation space increase

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidcooling system weight

Core Design Contradiction:

Object-generated harmful factorsVSWeight of stationary object

Solution Approach 1:

The battery cells themselves serve as part of the cooling system for the power electronics by acting as heat sinks. The thermal energy from electronics is transferred to battery cells through conductive elements, allowing the battery system to self-regulate thermal loads without requiring additional active cooling components, thereby reducing weight and space requirements.

Inventive Principle:

Principle #25Self-service

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 effectively compensates for the additional heat generated by power electronics using the battery cells' cooling system, reducing the complexity and cost of the cooling system while maintaining efficient heat transfer through a high temperature gradient, thus optimizing thermal management without significant additional expenditure.

Implementation Method 1

a heat-conducting element with a comb-shaped profile, distributing heat from the electronics over a large area of the cells

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The different thermal operating windows of electronics and battery cells provide a high temperature gradient which—assuming suitable structural measures—ensures a sufficiently strong flow of heat from the electronics into the cells

Methodology Applied

Scientific EffectTemperature gradient: Temperature Gradient

Data Source

PatentUS10759284B2Battery module for a traction battery

Publication Date: 2020.09.01 DR ING H C F PORSCHE AG

AI summary

A battery module for a traction battery having a housing, battery cells arranged inside the housing, a power electronics circuit board which is adjacent to the battery cells, a support face, facing away from the power electronics circuit board, for a cooling plate of the traction battery, and a heat-conducting element which bears over a surface on the power electronics circuit board and runs between the battery cells in the direction of or along the support face. Also described is a corresponding method for manufacturing a battery module, a corresponding traction battery and a corresponding electric car.