Multi-functional Cooling Channel and Busbar for Battery Pack
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery cell packs face challenges in efficiently integrating thermal and electrical connections, leading to increased complexity and component count, particularly in hybrid electric vehicles where lithium-ion batteries are used, due to asymmetric cell tabs and different cell types (N-type and P-type) requiring distinct part numbers and assembly configurations.
Innovation Solution
A multi-functional cooling channel and busbar design that serves as both a heat sink and electrical bus, allowing for one-sided electrical bussing and voltage sensing, reducing component complexity by using a single or dual channel designs for N-type and P-type cells, respectively, and enabling better thermal performance and compact packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling channels and busbars are used for thermal and electrical connections, then thermal management and electrical connectivity are achieved, but device complexity and component count increase
Solution Approach 1:
The patent combines separate cooling channels and busbars into a single integrated multi-functional component that simultaneously provides thermal management and electrical connectivity functions, thereby reducing device complexity and component count while maintaining both thermal and electrical performance
Solution Approach 2:
The integrated channel structure is designed to perform multiple functions: it serves as both a cooling channel for thermal management and a busbar for electrical current collection, enabling one component to fulfill the roles previously requiring separate components
2Reliability
If asymmetric cell tabs require distinct part numbers and assembly configurations for N-type and P-type cells, then proper electrical connections are achieved, but manufacturing complexity increases
Solution Approach 1:
The integrated channel design is configured to universally accommodate both N-type and P-type cells with asymmetric tabs through a single standardized component design, eliminating the need for different part numbers and reducing manufacturing complexity while ensuring proper electrical connections for all cell types
3Reliability
If traditional separate component integration is used, then functional requirements are met, but packing space increases
Solution Approach 1:
By merging the cooling channel and busbar into a single integrated component, the patent eliminates the space required for separate components and their individual mounting structures, thereby reducing overall packing space while maintaining all necessary thermal and electrical functions
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 simplifies the integration of battery cell groups by reducing the number of components needed for bussing and sensing, enhances thermal performance through tab and face cooling, and allows for versatile pack integration with the same electrical connections across different module layouts, thereby improving cost-effectiveness and efficiency.
Implementation Method 1
The first channel serves as a first heat sink to allow heat transfer from both the first lithium-ion battery cell and the second lithium-ion battery cell to the first channel
Data Source
AI summary
A prismatic battery stack includes a first lithium-ion battery cell and a second lithium-ion battery cell. The battery stack also includes a first channel disposed around the first lithium-ion battery cell and the second lithium-ion battery cell. The battery stack includes a second channel disposed around the first lithium-ion battery cell and the second lithium-ion battery cell. The first channel and the second channel serve as heat sinks.