Integrated Busbar Cooling Structure for Compact Battery Packs
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Solution Overview
Problem
Conventional battery packs suffer from low cooling efficiency and increased volume due to separate coolant circulation pipes, leading to potential thermal runaway and swelling, and require complex manufacturing processes.
Innovation Solution
The battery pack integrates a busbar and cooling member through insert injection molding, with the busbar being partially buried within a cooling member, allowing direct cooling and reducing volume increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coolant circulation pipe is attached above the busbar housing to cool the battery module, then heat removal is achieved, but cooling efficiency is low and the overall volume increases
Solution Approach 1:
The busbar housing is merged with the cooling member into a single integrated structure. The busbar housing serves dual functions as both an electrical connection component and a cooling component, eliminating the need for separate coolant circulation pipes above the busbar housing.
Solution Approach 2:
The busbar housing is designed to perform multiple functions simultaneously: electrical connection between battery cells and cooling of the battery module. The housing includes coolant circulation passages integrated within its structure, allowing it to serve as both a structural/electrical component and a thermal management component.
2Temperature
If a coolant circulation pipe is disposed above the busbars to remove heat, then heat removal is achieved, but cooling efficiency is low
Solution Approach 1:
The cooling function is merged directly into the busbar housing structure, placing the cooling member in direct contact with the busbars. This integration enables more efficient heat transfer from the busbars to the coolant compared to the conventional approach of disposing the coolant circulation pipe above the busbars.
Solution Approach 2:
The busbar housing acts as an intermediary heat transfer medium between the busbars and the coolant. The housing contains coolant circulation passages that allow coolant to flow in direct contact with or adjacent to the busbars, facilitating efficient heat removal through the housing structure.
3Temperature
If separate coolant circulation pipes are used to cool the battery module, then heat removal is achieved, but the manufacturing process becomes complex
Solution Approach 1:
The busbar housing and cooling member are merged into a single integrated component that can be manufactured as one piece using insert injection molding. This eliminates the need for separate assembly steps to attach coolant circulation pipes to the busbar housing, significantly simplifying the manufacturing process.
Solution Approach 2:
The cooling member is pre-formed as an integrated part of the busbar housing during the injection molding process. The coolant circulation passages are built into the housing structure before final assembly, eliminating subsequent assembly steps and reducing manufacturing complexity.
4Ease of manufacture
If the busbar and cooling member are separately manufactured and assembled, then manufacturing flexibility is maintained, but the manufacturing process is complex and time-consuming
Solution Approach 1:
The busbar housing and cooling member are combined into a single integrated component manufactured through insert injection molding. This allows both components to be produced simultaneously in one manufacturing cycle, dramatically improving production efficiency while maintaining design flexibility.
Solution Approach 2:
The cooling member is pre-formed within the busbar housing structure during the injection molding process itself. This preliminary integration of the cooling function into the housing manufacturing process eliminates separate assembly operations and accelerates production.
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 integration enhances cooling efficiency, simplifies manufacturing, and maintains stable temperature while minimizing volume, thereby improving energy density.
Implementation Method 1
heat generated in the battery module is removed by the coolant circulation pipe via the busbars, whereby the busbars are also cooled
Implementation Method 2
heat generated in the battery module is removed by the coolant circulation pipe via the busbars
Data Source
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AI summary
The present invention relates to a battery pack with improved cooling performance and a device including the same, and more particularly to a battery pack including a pack case (100) having a predetermined space defined therein; a plurality of battery modules (200) received in the pack case (100); a busbar (400) electrically connecting the plurality of battery modules (200) together; and a cooling member (500) provided under the pack case (100), wherein a predetermined region of the busbar (400) is located at the cooling member (500), and a device including the same.