Internal Busbar Battery Pack Thermal Management
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Solution Overview
Problem
The manufacturing of electric vehicle battery systems faces challenges in ensuring reliable electrical connections and efficient cooling of battery cells, which are crucial for maintaining optimal temperature and extending battery life, while also reducing manufacturing costs and increasing efficiency.
Innovation Solution
The use of internal busbars within the battery pack provides both electrical connections and thermally conductive paths for heat removal, with cooling plates integrated into the tray and busbar structure to manage heat effectively, allowing for efficient assembly and replacement of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate busbars and cooling plates are used, then electrical connections and cooling functions are achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the busbar and cooling plate into a single integrated component called an internal busbar. This internal busbar simultaneously provides electrical connection between battery cells and serves as a thermal conduction path for heat removal, eliminating the need for separate busbars and cooling plates, thus reducing structural complexity while maintaining both electrical and thermal functions
Solution Approach 2:
The internal busbar is designed to perform multiple functions: it acts as an electrical conductor for current flow between battery cells, a thermal conductor for heat transfer from battery cells, and a structural support element within the battery pack. This multi-functionality reduces the total number of components needed in the battery system
2Reliability
If multiple separate components are used for electrical connection and cooling, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
By merging the busbar and cooling plate functions into a single internal busbar component, the patent reduces the number of parts that need to be manufactured, stored, and assembled. This integration simplifies the supply chain and manufacturing processes while maintaining the safety and reliability functions of both electrical connection and thermal management
Solution Approach 2:
The internal busbar's multi-functional design allows a single component to fulfill multiple critical safety and operational requirements, reducing the overall bill of materials and manufacturing complexity while ensuring both electrical reliability and thermal management safety
3Temperature
If traditional cooling systems are used, then heat removal is achieved, but the battery pack design becomes less compact
Solution Approach 1:
The internal busbar is positioned within the battery cell structure, nesting the thermal management function inside the existing battery pack architecture rather than adding external cooling components. This nested arrangement allows heat conduction paths to be integrated within the battery cell volume, improving heat removal efficiency without increasing overall battery pack volume
4Productivity
If assembly processes are simplified, then manufacturing efficiency increases, but connection reliability may be compromised
Solution Approach 1:
The integration of busbar and cooling plate functions into a single internal busbar component reduces the number of assembly steps required, as fewer separate components need to be installed and connected. This simplification of the assembly process improves manufacturing efficiency while the integrated design ensures consistent electrical and thermal connections
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 solution enhances the reliability and safety of battery systems by ensuring efficient electrical connections and effective heat management, thereby extending battery life and reducing manufacturing costs, while allowing for more compact and efficient battery pack designs.
Implementation Method 1
a first cooling plate, connected with one of at least one of the lower tray and the second busbar, and at least one of the upper tray and the first busbar
Implementation Method 2
the first cooling plate is configured to conduct a cooling fluid therethrough
Data Source
AI summary
A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, a second busbar attached to the lower tray, and a plurality of battery cells arranged in the upper and lower trays between the first and second busbars. The first busbar is between the battery cells and the upper tray, and the second busbar is between the battery cells and the lower tray. The battery pack also includes a first cooling plate, connected with one of at least one of the lower tray and the second busbar, and at least one of the upper tray and the first busbar.