Integrated Busbar Cooling for Power Electronics

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Solution Overview

Problem

Existing battery module cooling systems are inefficient as they focus on cooling either the batteries or a singular system, failing to effectively manage heat generated by both busbars and power electronics, leading to reduced efficiency and safety concerns.

Innovation Solution

A cooling system that integrates both busbars and power electronics into a single heatsink, utilizing an active cooling interface for the busbars and leveraging the existing heatsink for power electronics, with a thermally conductive material and a fluid circulation system to enhance heat dissipation, reducing system cost and mass.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate cooling systems are used for busbars and power electronics, then each component can be cooled independently, but the system complexity and cost increase

Engineering Contradiction:

Improvecooling effectivenessVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines separate cooling systems for busbars and power electronics into a single integrated cooling system. The cooling device includes a first cooling channel for busbars and a second cooling channel for power electronics, both sharing common coolant flow paths and thermal management infrastructure, thereby reducing system complexity while maintaining effective cooling for both components

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If separate cooling systems are used for busbars and power electronics, then each component can be cooled independently, but the system cost and mass increase

Engineering Contradiction:

Improvecooling effectivenessVSAvoidsystem mass

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent integrates cooling infrastructure for both busbars and power electronics into a unified system, sharing common coolant reservoirs, pumps, and heat dissipation components. This consolidation reduces the total mass of cooling system components while ensuring both busbars and power electronics receive adequate cooling

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling system is designed with multi-functional capabilities, where a single cooling device performs multiple functions: cooling busbars through the first cooling channel, cooling power electronics through the second cooling channel, and providing shared thermal management infrastructure. This universal approach eliminates the need for separate dedicated cooling systems for each component

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If conventional cooling systems are used, then installation is straightforward, but heat dissipation efficiency is insufficient

Engineering Contradiction:

Improveinstallation simplicityVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The cooling system implements location-specific cooling channels optimized for each component's thermal characteristics. The first cooling channel is specifically designed for busbars with appropriate geometry and flow rates, while the second cooling channel is tailored for power electronics, ensuring each component receives optimal cooling tailored to its local thermal requirements

Inventive Principle:

Principle #3Local quality

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 integrated cooling solution effectively reduces busbar sizes, lowers overall system cost and mass, while ensuring efficient heat management for both busbars and power electronics, enhancing the operational efficiency and safety of battery modules.

Implementation Method 1

a cooling device, wherein the power electronics are mounted to the cooling device and the busbar, wherein the cooling device thermally cools both the power electronics and the busbar

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

with a thermally conductive material and a fluid circulation system to enhance heat dissipation

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS10608301B2Power electronics with integrated busbar cooling

Publication Date: 2020.03.31 NIO TECH ANHUI CO LTD

AI summary

Methods and systems for creating a battery module. A battery cell can include a cooling device that cools a busbar and a power electronics package. To allow the cooling device to be attached to the busbar and allow the cooling device to cool both the power electronics and the busbar, the cooling device is mounted on the busbar with the busbar held between two portions of the cooling device and with the power electronics mounted on an opposite side of the cooling device from the busbar. The fluid or phase change material may then circulate through a cavity in the cooling device to cool both the power electronics and the busbar.