Integrated Busbar Cooling Structure for Compact Battery Packs
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Solution Overview
Problem
Conventional battery packs face challenges in efficiently cooling busbars, leading to increased temperature and potential swelling or explosion due to low cooling efficiency and increased volume from coolant circulation pipes.
Innovation Solution
A battery pack design where a busbar and cooling member are integrally formed through insert injection molding, allowing direct cooling of the busbar and reducing the overall volume, thereby enhancing cooling efficiency and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coolant circulation pipe is attached above the busbar housing to cool the battery module, then cooling function is provided, but cooling efficiency is low and the overall volume of the battery module increases
Solution Approach 1:
The busbar and cooling member are merged into a single integrated component. The cooling member is formed integrally with the busbar through insert injection molding, eliminating the need for separate coolant circulation pipes attached above the busbar housing. This integration directly cools the busbar while removing the extra volume of separate cooling components, thereby improving cooling efficiency and reducing overall battery module volume.
2Temperature
If a coolant circulation pipe is attached above the busbar housing to cool the battery module, then cooling function is provided, but cooling efficiency is low
Solution Approach 1:
The cooling member is integrated directly with the busbar structure, allowing coolant to flow through channels formed within the busbar itself. This direct integration eliminates thermal transfer barriers between separate components, enabling more efficient heat removal from the busbar and significantly improving cooling efficiency compared to external pipe attachment.
3Temperature
If a coolant circulation pipe is attached above the busbar housing, then cooling function is provided, but the manufacturing process becomes complex
Solution Approach 1:
The busbar and cooling member are manufactured as a single integrated component using insert injection molding. This process allows the cooling channels to be formed directly within the busbar structure during manufacturing, eliminating the need for separate assembly steps to attach coolant circulation pipes. The integration simplifies the manufacturing process by reducing the number of parts and assembly operations required.
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 design effectively reduces the volume of the battery pack, improves cooling efficiency, and increases energy density by directly cooling the busbar, minimizing the risk of thermal runaway and swelling.
Implementation Method 1
a cooling member (500) provided under the pack case (100), wherein a predetermined region of the busbar (400) is located at the cooling member (500)
Data Source
AI summary
A battery pack includes a pack case. The battery pack also includes a plurality of battery modules in the pack case, a busbar that electrically connects the plurality of battery modules together. The battery pack also includes a cooling member under the pack case. A portion of the busbar is located proximate to the cooling member.