Battery Module Bus Bar Cooling Channels for Fast-Charging Heat
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Solution Overview
Problem
Large-sized battery modules face challenges in effectively cooling bus bars and electrode leads under high current and fast charging conditions, leading to increased temperature, potential performance deterioration, and safety risks due to inadequate heat dissipation.
Innovation Solution
A battery module design incorporating a cooling flow path within the bus bar, allowing coolant to flow through the bus bar, which connects the electrode leads and bus bars, enhancing heat dissipation and temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to increase capacity and output, then the energy density and power output are improved, but the heat generation increases and heat dissipation becomes more difficult
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels (first cooling channel, second cooling channel, third cooling channel) that are distributed throughout the battery module. Each channel independently cools specific battery cells, allowing heat to be dissipated from multiple locations simultaneously, thereby effectively managing heat generation from large numbers of stacked battery cells.
Solution Approach 2:
A cooling plate is introduced as an intermediary component between the battery cells and the external environment. The cooling plate contains internal cooling channels that circulate coolant, serving as a heat transfer medium. This intermediary structure efficiently captures heat from multiple battery cells and transfers it to the coolant flowing through the channels, solving the heat dissipation problem in high-power battery modules.
2Productivity
If high current is used for fast charging, then the charging speed is improved, but the heat generation from bus bars and electrode leads increases
Solution Approach 1:
A coolant circulation system using hydraulic principles is implemented to manage heat from high current operations. The coolant flows through cooling channels in the cooling plate, utilizing fluid circulation to continuously remove heat generated during fast charging. This hydraulic cooling approach efficiently manages the thermal load from high current without compromising charging speed.
Solution Approach 2:
The cooling system dynamically adjusts parameters such as coolant flow rate and temperature to match the thermal load during fast charging. When high current is applied for rapid charging, the system increases coolant circulation and adjusts thermal management parameters to maintain optimal operating temperatures, enabling sustained high-power operation without excessive heat accumulation.
3Device complexity
If conventional cooling structure is used, then the device complexity is kept low, but the heat dissipation effectiveness is insufficient for high power applications
Solution Approach 1:
The cooling plate serves multiple functions simultaneously: it provides structural support for the battery cells, contains the cooling channels for heat dissipation, and acts as a thermal management system. This multi-functional design achieves effective heat dissipation for high-power applications without proportionally increasing device complexity, as the cooling plate integrates several functions into a single component.
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 solution effectively cools battery cells and bus bars, stabilizes internal temperatures, and improves the safety and performance of the battery module by minimizing temperature deviations and preventing overheating.
Implementation Method 1
heat generated from the bus bar is conducted to the cooling water flowing in the cooling flow path
Implementation Method 2
cooling water flowing in the cooling flow path... the cooling water may comprise an insulated cooling water
Data Source
AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack including a plurality of battery cells; a module frame surrounding the battery cell stack; a bus bar frame that covers a portion of the battery cell stack exposed from the module frame; and a bus bar mounted on the bus bar frame and connected to an electrode lead protruding from the battery cell stack, wherein a cooling flow path is formed in the bus bar.