Embedded Bus Bar Lid Structure for Battery Pack Cooling
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Solution Overview
Problem
Existing battery packs suffer from reduced cooling efficiency due to the heat sink being separate from the bus bar, leading to increased distances and decreased thermal conductivity.
Innovation Solution
The bus bars are embedded within the lid part of the battery case, with connection terminals exposed to the inner face of the lid part, allowing direct contact with a cooler for improved heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the heat sink is attached to the pack cover as a separate body, then the structural simplicity is maintained, but the cooling efficiency is reduced due to increased distances between the heat sink and bus bar/battery module
Solution Approach 1:
The bus bar is embedded within the lid part, merging two previously separate components (bus bar and lid part) into a single integrated structure. This eliminates the need for separate mounting and reduces thermal resistance between the bus bar and cooler, directly resolving the contradiction by improving cooling efficiency while maintaining structural simplicity through integration.
Solution Approach 2:
The bus bar is nested within the lid part structure, with the lid part serving as both a structural component and a mounting medium for the bus bar. This nesting arrangement allows the bus bar to be positioned in close proximity to the cooler while the lid part provides both mechanical support and thermal conduction path, resolving the contradiction between structural simplicity and cooling efficiency.
2Loss of energy
If the bus bar is embedded in the lid part, then the cooling efficiency is improved through reduced thermal resistance, but the manufacturing complexity increases
Solution Approach 1:
The bus bar and lid part are merged into a single integrated component, which can be manufactured as one piece using processes like die-casting or injection molding. This integration improves cooling efficiency by eliminating thermal interface resistance while the one-step manufacturing process actually reduces overall manufacturing complexity compared to assembling separate parts.
Solution Approach 2:
The lid part is formed as a composite structure incorporating both the insulating material and the conductive bus bar element. This composite approach allows simultaneous achievement of electrical insulation, thermal conduction to the cooler, and mechanical strength, while simplifying manufacturing by creating a single multi-functional component.
3Ease of operation
If the connection terminals are exposed from the inner face of the lid part, then the electrical connection is facilitated, but the insulation risk increases
Solution Approach 1:
The lid part exhibits local quality differentiation: the regions where connection terminals are exposed maintain electrical conductivity for connection purposes, while the embedded portions provide electrical insulation. This localized functional differentiation allows easy electrical connection where needed while maintaining insulation reliability in other areas, resolving the contradiction between connection ease and insulation reliability.
Solution Approach 2:
The lid part itself serves as an intermediary element that provides both electrical connection functionality (through exposed terminals) and insulation functionality (through embedded portions). This dual-role intermediary resolves the contradiction by integrating both connection and insulation functions into a single component rather than requiring separate elements.
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 configuration enhances cooling efficiency by reducing thermal resistance and increasing the surface area for heat exchange, while ensuring insulation and rigidity, thus improving the overall performance of the battery pack.
Implementation Method 1
heat exchange with the cooler may be conducted efficiently
Data Source
AI summary
A battery pack that may improve cooling efficiency. The battery pack includes plural battery cells that each include a positive electrode terminal and a negative electrode terminal, a battery case that accommodates the plural battery cells, a lid part that is formed of an insulator and provided at the battery case, and bus bars. The bus bars each include a main body portion embedded in the lid part, and connection terminals provided at end portions of the main body portion. The connection terminals are exposed from an inner face of the lid part that opposes the plural battery cells, and are electrically connected with the positive electrode terminals and negative electrode terminals of the plural battery cells. An outer face of the lid part is in contact with a cooler.