Terminal Bushing with Integrated Coolant Passage for Battery Thermal Management
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Solution Overview
Problem
Current battery pack designs face challenges in achieving electrical and thermal homogeneity, leading to inefficient temperature management and potential safety issues due to thermal runaway and gas generation, which affects the performance and lifespan of metal-ion batteries.
Innovation Solution
A modular battery module design featuring a tube housing multiple metal-ion accumulators connected in series with a common heat transfer fluid circuit, allowing for continuous coolant flow around the accumulators and within the module, enhancing thermal management and safety through integrated gas detection and control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional battery pack design is used with separate terminal connections, then electrical connection is achieved, but thermal homogeneity and safety are compromised due to inadequate thermal management
Solution Approach 1:
The patent merges the electrical terminal connection function with the thermal management function by integrating a heat transfer fluid circuit passage through the terminal bushing. The bushing that provides electrical connection also serves as a conduit for coolant flow, combining two separate functions into one component. This integration ensures that thermal management is inherently tied to the electrical connection structure, improving thermal homogeneity without compromising safety.
Solution Approach 2:
The terminal bushing is designed to perform multiple functions simultaneously: providing electrical connection between accumulators, serving as a mechanical support structure, and acting as a conduit for heat transfer fluid circulation. This multi-functional design eliminates the need for separate thermal management components, ensuring that thermal control is embedded in the basic structural elements of the battery pack.
2Reliability
If accumulators are connected in series without integrated thermal management, then electrical series connection is achieved, but temperature uniformity deteriorates leading to thermal runaway risks
Solution Approach 1:
The battery pack is divided into modular accumulator units, each with its own terminal bushing that includes integrated heat transfer fluid passages. This segmentation allows each accumulator to have dedicated thermal management, ensuring uniform temperature distribution across the entire series-connected string while maintaining electrical connectivity. The modular approach enables independent thermal control of each unit.
Solution Approach 2:
The heat transfer fluid circuit is pre-integrated into the terminal bushing structure before the accumulators are assembled into the battery pack. This preliminary integration ensures that thermal management pathways are established in advance, allowing heat to be efficiently dissipated from each accumulator as it is connected in series, preventing temperature buildup before thermal runaway can occur.
3Ease of operation
If traditional terminal designs are used, then electrical connection is provided, but thermal management efficiency is reduced due to lack of integrated coolant flow
Solution Approach 1:
The electrical connection function and thermal management function are merged into a single integrated terminal bushing component. The bushing provides both the electrical conduit for current flow and the fluid dynamic pathway for coolant circulation, eliminating energy losses associated with separate connection mechanisms and improving overall thermal management efficiency.
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 improves temperature uniformity and safety within the battery pack, extending its lifespan and optimizing power, size, and weight efficiency while preventing thermal runaway and gas-related issues.
Implementation Method 1
a heat transfer fluid circuit configured to cause a heat transfer fluid to circulate inside the accumulators at least over the length of the mandrels
Implementation Method 2
an electrochemical cell C formed of a cathode, an anode and an electrolyte interposed between the cathode and the anode
Data Source
Figure 1~5
Figure 6~8A
Figure 9~12
AI summary
The invention relates to a terminal-forming through-hole, made through an opening on either side of a wall of the casing of an accumulator, comprising: - an electrically conductive male part (5), internally comprising a passage opening to the outside of the accumulator and intended to circulate a cooling fluid which has circulated along the longitudinal axis of the accumulator; - an electrically conductive female part (50), tightly fitted around a part of the male part, outside the accumulator; - two electrically insulating washers (48, 49), each comprising a bearing portion in surface contact with pressure against both one of the faces of the wall and a guide portion projecting from the bearing portion and in contact with the edge of the opening; the bearing portions of the washers being in contact with pressure against the female part and against a part of the male part.