Battery Pack Bus Bar Cooling for Large Cylindrical Cells
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Solution Overview
Problem
Traditional cooling methods for large battery cells in electric vehicles, such as the bottom cooling method, face limitations in achieving effective heat dissipation as the size of battery cells increases, particularly with circular cells, where the diameter and height enlargement restrict efficient cooling.
Innovation Solution
A battery pack design incorporating a connection cooling member that extends integrally with the electrode along the outer circumferential surface of the battery cell, featuring a bus portion and cooling portions made of the same metal, which electrically connects and thermally dissipates heat from the battery cells, improving heat transfer efficiency while serving as a bus bar, and is coupled to a holder via an insert-injection or adhesion structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bottom cooling method is used for large battery cells, then the cooling structure is simple, but the cooling effectiveness deteriorates due to increased cell size
Solution Approach 1:
The patent combines the electrical connection function (bus bar) and cooling function into a single integrated component. The connection cooling member includes a bus portion for electrical connection and cooling portions extending along the battery cell surface, eliminating the need for separate cooling structures and improving heat dissipation effectiveness for large cells
Solution Approach 2:
The cooling portions extend along the outer circumferential surface of the battery cell in a longitudinal direction, transitioning from traditional bottom-only cooling to multi-dimensional surface cooling. This dimensional expansion allows effective heat dissipation from large cells by utilizing the side surface area
2Temperature
If separate cooling structures are added to battery cells, then cooling effectiveness improves, but device complexity increases
Solution Approach 1:
The connection cooling member performs multiple functions simultaneously: it provides electrical connection between battery cells through the bus portion, serves as a heat dissipation structure through the cooling portions contacting the cell surface, and acts as a structural support element. This multi-functionality eliminates the need for separate cooling structures
Solution Approach 2:
The patent merges the electrical connection component (bus bar) and cooling component into a single integrated connection cooling member, reducing the number of parts and simplifying the overall structure while maintaining both electrical and thermal functions
3Adaptability or versatility
If multiple separate components are used for connection and cooling, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The connection cooling member is manufactured as a single integrated component combining the bus portion and cooling portions, reducing part count, simplifying assembly processes, and lowering manufacturing costs while meeting both electrical connection and cooling functional requirements
Solution Approach 2:
The integrated connection cooling member serves multiple functions (electrical connection and heat dissipation) simultaneously, eliminating the need for multiple separate components and reducing overall material and manufacturing costs
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 heat dissipation by allowing quick transfer of heat from the battery cells through the connection cooling member, optimizing space utilization and reducing material and process costs compared to conventional side cooling methods, while maintaining electrical insulation and improving durability.
Implementation Method 1
a connection cooling member extending from the end of the at least one battery cell towards the opposite end of the at least one battery cell along the outer circumferential surface of the at least one battery cell
Implementation Method 2
The bus portion may electrically connect the plurality of battery cells arranged in the first column and the second column
Data Source
AI summary
A battery pack including at least one battery cell including an electrode at an end of the at least one battery cell and an outer circumferential surface extending between the end and an opposite end of the at least one battery cell; and a connection cooling member extending from the end of the at least one battery cell towards the opposite end of the at least one battery cell along the outer circumferential surface of the at least one battery cell the connection cooling member and the electrode including a same metal and being integral with each other.