Battery Pack Thermal Exchange Frame With Integrated Busbar Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems in electrified vehicles face challenges in managing thermal energy levels efficiently, particularly within battery arrays, which can lead to overheating and reduced performance.
Innovation Solution
A thermal exchange assembly is introduced, comprising a polymer-based thermal exchange frame that holds busbars and a conduit, which manages thermal energy levels by circulating coolant through the frame and conduit, enhancing thermal conductivity and reducing packaging space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate busbar holding modules are used, then structural support is provided, but device complexity and packaging space increase
Solution Approach 1:
The patent combines the busbar holding function with the thermal exchange frame into a single integrated structure. The frame includes recesses that receive and secure busbars, eliminating the need for separate busbar holding modules while maintaining structural support and reducing overall device complexity
Solution Approach 2:
The thermal exchange frame serves multiple functions simultaneously: it provides structural support through its rigid construction, holds busbars via integrated recesses, and manages thermal energy through coolant flow channels. This multi-functionality reduces the number of separate components needed in the battery pack
2Volume of stationary object
If polymer-based thermal exchange frame is used, then packaging space is reduced, but thermal conductivity may be insufficient
Solution Approach 1:
The patent employs a polymer-based thermal exchange frame that integrates metal components (such as aluminum or copper) into the polymer structure. This composite approach allows the frame to maintain the packaging space advantages of polymers while achieving sufficient thermal conductivity through the metal elements that conduct heat from the battery cells to the coolant channels
Solution Approach 2:
The frame uses polymer material in regions where structural support and space efficiency are priorities, while incorporating metal materials in specific locations where high thermal conductivity is needed, such as at contact points with battery cells or in coolant flow paths, optimizing the balance between packaging space and thermal management performance
3Temperature
If thermal exchange frame communicates coolant between busbars and battery cells, then thermal management is improved, but device complexity increases
Solution Approach 1:
The patent integrates the coolant communication system directly into the thermal exchange frame structure. The frame includes built-in channels or passages that allow coolant to flow between the busbars and battery cells, eliminating the need for separate tubing or piping systems and reducing overall device complexity while maintaining effective thermal management
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 assembly effectively manages thermal energy levels, maintaining optimal operating temperatures and reducing the need for separate busbar holding modules, thereby improving battery performance and safety.
Implementation Method 1
a thermal exchange assembly that can manage thermal energy levels of a battery array and also holds busbars of the battery array. A coolant can be moved through the thermal exchange assembly to manage thermal energy levels
Implementation Method 2
a polymer-based thermal exchange frame that holds busbars and a conduit, which manages thermal energy levels by circulating coolant through the frame and conduit, enhancing thermal conductivity
Data Source
AI summary
A traction battery assembly, includes a thermal exchange frame configured to communicate a coolant that manages thermal energy levels within a traction battery pack, and an plurality of busbars held by the thermal exchange frame. A thermal management method includes moving a coolant through a thermal exchange frame to manage thermal energy levels of a battery array, and holding a plurality of busbars with the thermal exchange frame.