Battery Disconnect Unit Cooling Plate Integration for Lower Power Loss
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Solution Overview
Problem
Existing battery systems face inefficiencies in cooling and assembly processes for battery disconnecting units (BDUs), leading to increased resistance, power loss, and potential electrical malfunctions due to inadequate cooling methods, particularly in high-voltage systems.
Innovation Solution
A battery system with an integrated liquid cooling plate and carrier plate design, where the high-voltage line is partially embedded within the carrier plate, allowing for efficient cooling of BDU components, reduced busbar size, and improved insulation, along with a modular PCB design for simplified assembly and component integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional cooling methods are used for BDU components, then the cooling system is simpler, but cooling efficiency is insufficient leading to increased resistance and power loss
Solution Approach 1:
The patent combines the cooling plate with the carrier plate into a single integrated structure. The cooling plate is positioned on the front surface of the carrier plate to form an integrated assembly that provides efficient cooling to BDU components while reducing the number of separate parts and simplifying the overall system architecture
Solution Approach 2:
The high-voltage line is embedded within the carrier plate, creating a nested structure where the conductive path is integrated into the body of the carrier plate. This nesting approach reduces the overall system footprint and improves thermal management by placing cooling channels in close proximity to heat-generating components
2Power
If busbars are made larger to handle high current, then current carrying capacity increases, but resistance and weight increase
Solution Approach 1:
The patent changes the physical state and properties of the high-voltage line by embedding it within the carrier plate structure. This integration allows for optimized cross-sectional area and material selection that reduces resistance while maintaining current carrying capacity, thereby reducing weight without sacrificing power handling capability
Solution Approach 2:
The integrated cooling plate and carrier plate structure utilizes composite material design where conductive materials for the high-voltage line are combined with thermally conductive but electrically insulating carrier plate material. This composite approach enables efficient current flow while managing heat dissipation and reducing overall weight
3Ease of manufacture
If BDU components are integrated into the carrier plate, then assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the BDU into distinct functional modules: the carrier plate structure, the integrated high-voltage line, the cooling plate, and the BDU relays. This segmentation allows each component to be manufactured and tested separately with standard tolerances, then assembled together, reducing the need for high-precision integrated manufacturing while simplifying assembly procedures
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 enhances cooling efficiency, reduces resistance and weight, and simplifies assembly, enabling higher load applications and improved reliability of the BDU components, particularly in high-voltage systems.
Implementation Method 1
a liquid cooling plate on a first side of the carrier plate. The liquid cooling plate includes a cavity configured to conduct a cooling liquid
Implementation Method 2
a liquid cooling plate on a first side of the carrier plate... the liquid cooling plate includes a cavity configured to conduct a cooling liquid
Data Source
AI summary
A battery system includes: a high voltage (HV) system having a plurality of connected rechargeable battery cells; a battery disconnecting unit (BDU) comprising a carrier plate, BDU relays configured to switchably open or close a HV line of the HV system, wherein the HV line is at least partially integrated into the carrier plate, and a BDU control unit configured to control the BDU relays; and a liquid cooling plate on a first side of the carrier plate.