Curved Thermal Bridge for Battery-Integrated Power Electronics Cooling
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Solution Overview
Problem
Conventional battery systems with integrated power electronics lack effective thermal management, as they do not adequately address the heat generated by both energy storage units and power electronics systems, leading to potential overheating and reduced battery performance.
Innovation Solution
A method and system that utilize a thermally conductive element with a curved portion to establish direct thermal contact between the power electronics system and energy storage units, allowing for efficient heat transfer to the battery housing, which is then coupled to a cooling system, thereby managing the thermal energy generated by both sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a power electronics system is integrated in a battery module, then the system can handle high currents and improve power management, but additional heat sources are generated that complicate thermal management
Solution Approach 1:
The patent merges the cooling of two separate heat sources (battery cells and power electronics system) into a single integrated cooling system. The power electronics system is thermally coupled to the battery module housing, which serves as a common heat discharge path, eliminating the need for separate cooling systems and reducing overall system complexity.
Solution Approach 2:
The battery module housing serves multiple functions: it provides structural support, electrical insulation, and acts as a thermal management system. The housing is designed with thermally conductive properties to function as a heat sink for both the battery cells and the power electronics system, consolidating multiple functions into a single component.
2Temperature
If conventional battery cooling systems are used, then battery cells are cooled effectively, but the power electronics system overheats due to insufficient thermal capacity
Solution Approach 1:
The patent combines the thermal management of the battery cells and power electronics system into a unified cooling approach. The power electronics system is thermally coupled to the battery module housing, which shares the same cooling fluid circulation system used for battery cell cooling, ensuring both components are cooled simultaneously through a common thermal pathway.
3Reliability
If the power electronics system is thermally isolated, then electrical insulation is improved, but heat dissipation becomes insufficient leading to overheating
Solution Approach 1:
The patent introduces a thermally conductive intermediary structure (the battery module housing) that serves as a thermal bridge between the power electronics system and the cooling system. This intermediary maintains electrical insulation while providing an efficient heat dissipation pathway, resolving the contradiction between electrical isolation and thermal management.
4Device complexity
If the battery housing is used for heat discharge, then the cooling system complexity is reduced, but the power electronics thermal coupling must be optimized
Solution Approach 1:
The patent employs a curved or contoured thermal interface between the power electronics system and the battery module housing to maximize contact area and improve thermal coupling. This geometric adaptation ensures optimal thermal contact while accommodating manufacturing tolerances, reducing the need for high-precision assembly.
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 approach effectively compensates for the thermal energy differences between the power electronics and energy storage units, allowing for high heat flow and distribution, preventing overheating and ensuring reliable operation by integrating the power electronics system with the existing battery cooling system.
Implementation Method 1
a thermally conductive element (102) which creates thermal contact between the respective energy storage units (116) and the power electronics system (404)
Implementation Method 2
wherein a spring action between the power electronics system (404) and the thermally conductive element (102) is formed by the curved portion (202)
Data Source
AI summary
Method for providing cooling of a power electronics system which is integrated in a battery module, in which method the battery module has a battery housing, containing a large number of energy storage units and the power electronics system which is integrated adjacent thereto and includes a printed circuit board which is populated with power semiconductor switches, and a thermally conductive element which creates thermal contact between the respective energy storage units and the power electronics system. Cooling of the power electronics system is achieved by the thermally conductive element which renders possible transfer of thermal energy from the power electronics system to the energy storage units. At least one side of the battery housing is coupled to a cooling system. A surface area of the thermally conductive element is connected to a respective energy storage unit and is contacted by way of a respective curved portion.