Battery Busbar Conduit With Thermal Bridge for Safe Cooling

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Solution Overview

Problem

Thermal energy management in traction battery packs is inefficient, leading to potential overheating issues without effective passive or active thermal management strategies.

Innovation Solution

A conduit system with integrated thermal bridges within busbars that facilitates thermal energy transfer using a thermal management fluid, sealed to prevent electrical contact and leakage, utilizing a polymer-based conduit and metal or metal alloy thermal bridges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal management fluid is used to cool busbars, then thermal energy management efficiency is improved, but electrical shorts between busbars and conduit may occur

Engineering Contradiction:

Improvethermal energy management efficiencyVSAvoidelectrical short prevention

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent introduces a thermal bridge as an intermediary component between the busbar and the thermal management fluid. The thermal bridge is electrically isolated from the fluid through a seal, allowing thermal energy transfer while preventing electrical conduction. This mediator enables heat exchange without creating an electrical short circuit between the conductive busbar and the fluid.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the thermal management system into distinct functional zones: the conduit containing the thermal management fluid, the seal providing electrical isolation, and the thermal bridge facilitating heat transfer. This segmentation allows each component to perform its specific function while maintaining electrical safety and thermal efficiency.

Inventive Principle:

Principle #1Segmentation

2Temperature

If thermal bridges are integrated into busbars for thermal transfer, then thermal transfer efficiency is enhanced, but electrical isolation from thermal management fluid becomes critical

Engineering Contradiction:

Improvethermal transfer efficiencyVSAvoidelectrical isolation requirements

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the thermal bridge with the busbar structure, creating an integrated component that performs both electrical conduction and thermal transfer functions. The thermal bridge is formed as part of the busbar assembly, eliminating the need for separate thermal coupling components and simplifying the overall structure while maintaining electrical isolation through the seal.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite material strategies by combining the conductive busbar material with the isolating seal material. The seal acts as a composite interface between the metal busbar/thermal bridge and the thermal management fluid, providing both mechanical support and electrical isolation properties.

Inventive Principle:

Principle #40Composite materials

3Reliability

If polymer-based conduit is used, then electrical isolation is provided, but manufacturing precision for sealing interfaces becomes challenging

Engineering Contradiction:

Improveelectrical isolationVSAvoidsealing interface precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent utilizes the specific parameters of polymer materials, particularly their flexibility and moldability, to create effective seals. The polymer conduit can be molded to precisely fit the thermal bridge and busbar interfaces, accommodating manufacturing tolerances while maintaining reliable electrical isolation. The material properties are selected to balance isolation effectiveness with manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

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

Effectively manages thermal energy within traction battery packs by preventing electrical shorts while enhancing thermal transfer efficiency and maintaining fluid containment.

Implementation Method 1

moving a thermal management fluid through the conduit to exchange thermal energy with the thermal bridge

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Implementation Method 2

the thermal management fluid moves through the conduit over a first side of the thermal bridge, and through the conduit over an opposite, second side of the thermal bridge

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12519152B2Traction battery conduit and thermal bridge assembly

Publication Date: 2026.01.06 FORD GLOBAL TECH LLC

AI summary

A traction battery assembly includes a conduit having an interior that carries a thermal management fluid. A thermal bridge extends into the conduit and spans across the interior from a first side of the conduit to an opposite, second side of the conduit. A traction battery thermal transfer method includes positioning a thermal bridge relative to a conduit such that the thermal bridge extends across an interior of the conduit from a first side of the conduit to an opposite, second side of the conduit, and moving a thermal management fluid through the conduit to exchange thermal energy with the thermal bridge.