Integrated Bus Bar and Coolant Manifold for EV Battery Thermal Management
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Solution Overview
Problem
In electric vehicle battery systems, the size and efficiency of energy storage are compromised due to the space required by separate bus bars and coolant manifolds, which also lead to increased resistive heating and reduced storage capacity.
Innovation Solution
Integration of bus bars and coolant manifolds into a combined carrier structure, allowing for coaxial configurations that conserve space and enable liquid cooling of bus bars, reducing their size and minimizing resistive heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If separate bus bars and coolant manifolds are used, then electrical connectivity and thermal management are achieved, but space efficiency is reduced and system size increases
Solution Approach 1:
The patent combines the bus bar and coolant manifold into a single integrated component. The bus bar structure incorporates internal coolant flow channels, allowing electrical current conduction and thermal management functions to be performed by one component rather than two separate parts. This merging reduces overall system volume and improves space efficiency while maintaining both electrical and thermal functions.
Solution Approach 2:
The integrated bus bar manifold serves multiple functions simultaneously: it conducts electrical current between battery modules, provides thermal management through internal coolant flow, and acts as a structural support element. This multi-functionality eliminates the need for separate dedicated components for each function, reducing system complexity and manufacturing steps.
2Loss of energy
If larger bus bars are used to reduce resistive heating, then electrical efficiency improves, but space for energy storage decreases
Solution Approach 1:
The patent transitions from a solid bus bar design to a hollow bus bar with internal coolant channels. This dimensional change allows the bus bar to carry coolant through its interior, adding a thermal management function without significantly increasing external dimensions. The internal volume is utilized for coolant flow, enabling heat removal that reduces resistive heating effects while maintaining compact overall size.
Solution Approach 2:
Coolant flowing through the internal channels of the bus bar acts as an intermediary heat transfer medium. It absorbs heat generated by resistive heating in the bus bar and transfers it away, effectively reducing the thermal load and energy loss without requiring the bus bar itself to be larger.
3Volume of moving object
If integrated bus bar and coolant manifold structure is used, then space efficiency and thermal management improve, but manufacturing complexity increases
Solution Approach 1:
The bus bar and coolant manifold are merged into a single integrated component with the coolant channels formed within the bus bar structure. This consolidation reduces the number of separate parts and assembly steps, and while the internal geometry is complex, the overall device complexity is reduced by eliminating interfaces between separate components.
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 space efficiency, reduces bus bar size, and maintains optimal operating temperatures within the battery pack, thereby improving energy storage capacity and thermal management.
Implementation Method 1
a cooling system configured to circulate a fluid dielectric through the at least one battery module along a flow path comprising the coolant manifold
Implementation Method 2
a bus bar connected to the terminal, the bus bar configured to electrically connect the at least one terminal to an external terminal of the battery system
Implementation Method 3
reduces their size and minimizing resistive heating
Implementation Method 4
enable liquid cooling of bus bars
Data Source
AI summary
Fluid cooled electric vehicle battery systems are disclosed. Systems can include an integrated coolant manifold and bus bar configured to carry coolant and electrical current along a common or coaxial path. An integrated coolant manifold and bus bar can include a conductive layer surrounding a coolant flow path and/or a conductor disposed within a coolant flow path. Integrated coolant manifold and bus bar structures may improve efficient use of battery space by reducing the number of battery components and by allowing reduced bus bar size due to fluid cooling of the bus bar.