Multi-Layer Contact Plate for Low-Loss Battery Module Bonding
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Solution Overview
Problem
Conventional battery module designs face challenges in efficiently connecting battery cells due to difficulties in joining steel terminal contacts with busbars, leading to high power loss and inefficient cooling mechanisms that consume excessive electrical power and interfere with cell terminal connections.
Innovation Solution
A hybrid contact plate arrangement with multi-layer contact plates, featuring a primary conductive layer and a cell terminal connection layer, is used to connect battery cells in parallel and series configurations, allowing for direct axial cooling and reducing assembly complexity by positioning all terminals on the same side, thereby facilitating efficient electrical bonding and improved current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional busbars are used to connect steel terminal contacts, then electrical connections can be established, but power loss increases due to joining difficulties
Solution Approach 1:
The contact plate merges the electrical connection function and cooling function into a single integrated component. The contact plate directly contacts the terminal contacts of battery cells while simultaneously serving as a cooling element through which coolant flows, eliminating the need for separate busbars and cooling mechanisms.
Solution Approach 2:
The contact plate is made of aluminum or aluminum alloy material instead of conventional steel busbars. Aluminum provides both excellent electrical conductivity to reduce power loss and good thermal conductivity for efficient cooling, while being easier to join with terminal contacts.
2Temperature
If cooling mechanisms are implemented in conventional designs, then battery cells can be cooled, but the mechanisms consume excessive electrical power and interfere with cell terminal connections
Solution Approach 1:
The contact plate incorporates internal coolant channels through which liquid coolant flows to provide passive cooling. This hydraulic cooling system replaces active electrical cooling mechanisms, consuming no electrical power while efficiently removing heat from battery cells through convection and conduction.
3Reliability
If multi-layer contact plates with insulation layers are used, then electrical insulation between contact plates is provided, but assembly complexity increases
Solution Approach 1:
The insulation layer is integrated as part of the contact plate structure itself rather than being a separate component. The multi-layer construction includes conductive layers for electrical connection and insulating layers for electrical isolation, all formed as a single assembled unit that simplifies the overall assembly process.
4Device complexity
If all terminals are positioned on the same side of battery cells, then assembly complexity is reduced and electrical bonding is facilitated, but conventional connection methods cannot be used
Solution Approach 1:
The contact plate extends in multiple spatial dimensions to reach terminals positioned on the same side of battery cells. The elongated contact plate structure with multiple contact points allows electrical connections to be made from a single side, transitioning from conventional two-sided terminal access to one-sided access architecture.
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
The hybrid contact plate arrangement enhances electrical connectivity, reduces power loss, and allows for more efficient cooling of battery cells, improving the overall performance and efficiency of battery modules by minimizing interference between cooling mechanisms and cell connections.
Implementation Method 1
the sets of bonding connectors being configured to connect to the positive and negative terminals of the plurality of groups of battery cells so as to connect battery cells in each of the plurality of groups of battery cells in parallel with each other, and to connect the plurality of groups of battery cells in series with each other
Implementation Method 2
at least one insulation layer configured to provide insulation between each of the plurality of contact plates
Data Source
AI summary
An embodiment is directed to a hybrid contact plate arrangement in a battery module that includes a plurality of contact plates configured to be arranged on a given side of a set of battery cells in the battery module, at least one insulation layer configured to provide insulation between each of the plurality of contact plates, wherein the set of battery cells includes a plurality of groups of battery cells, and wherein the plurality of contact plates each include a set of bonding connectors, the sets of bonding connectors being configured to connect to the positive and negative terminals of the plurality of groups of battery cells so as to connect battery cells in each of the plurality of groups of battery cells in parallel with each other, and to connect the plurality of groups of battery cells in series with each other.