Battery Module Busbar Cooling Through Insulated Heat Transfer

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Solution Overview

Problem

Conventional battery modules face challenges in effectively cooling the busbar due to indirect heat transfer methods, which are inadequate for high current and fast charging environments, leading to heat generation issues.

Innovation Solution

A battery module design featuring a busbar directly connected to a cooling fin, with a heat transfer member providing electrical insulation and thermal conductivity, allowing for sequential heat transfer through a thermal conductive resin layer and cooling plate for efficient heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional cooling structure with busbar separated from cooling fin by busbar frame is used, then the structural integrity and electrical insulation are maintained, but heat transfer efficiency is insufficient leading to heat generation in high current environments

Engineering Contradiction:

Improvebusbar temperatureVSAvoidheat transfer efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent introduces a heat transfer member as an intermediary component between the busbar and cooling fin. This mediator enables thermal conduction while maintaining electrical insulation, allowing efficient heat transfer from the busbar to the cooling fin without direct electrical contact. The heat transfer member resolves the contradiction by providing a thermal pathway that does not compromise electrical isolation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cooling structure is segmented into distinct functional components: the busbar for electrical conduction, the heat transfer member for thermal conduction with electrical insulation, and the cooling fin for heat dissipation. This segmentation allows each component to optimize its specific function while working together as an integrated thermal management system.

Inventive Principle:

Principle #1Segmentation

2Productivity

If high current is used for fast charging, then charging speed is improved, but heat generation in the busbar increases

Engineering Contradiction:

Improvecharging speedVSAvoidbusbar temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent converts the harmful heat generated by high current fast charging into a manageable thermal transfer process. By providing a dedicated heat transfer member that efficiently conducts heat away from the busbar, the system transforms the unwanted thermal byproduct of fast charging into a controlled heat dissipation process, enabling high current operation without excessive temperature rise.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of energy

If direct contact between busbar and cooling fin is made for efficient heat transfer, then heat transfer efficiency improves, but electrical insulation is compromised

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidelectrical insulation

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The heat transfer member serves as a mediator that provides both thermal conduction and electrical insulation. It creates a thermal pathway from the busbar to the cooling fin while simultaneously maintaining electrical isolation, thus achieving efficient heat transfer without compromising the electrical insulation between conductive components.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heat transfer member is made of a composite material or material with specific properties that combine thermal conductivity with electrical insulation. This allows the single component to fulfill dual functions: transferring heat effectively while preventing electrical current flow, resolving the contradiction between heat transfer efficiency and electrical insulation.

Inventive Principle:

Principle #40Composite materials

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 solution effectively addresses heat generation in high current and fast charging scenarios by providing a direct cooling path for the busbar, enhancing the stability and energy efficiency of the battery module.

Implementation Method 1

a heat transfer member provided between the busbar and the cooling fin, having an electrical insulation property and a thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

allowing for sequential heat transfer through a thermal conductive resin layer and cooling plate for efficient heat dissipation

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP4131579B1Battery module and battery pack comprising same

Publication Date: 2024.12.25 LG ENERGY SOLUTION LTD

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AI summary

A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked, a module frame that wraps the battery cell stack, a busbar frame that covers a portion of the battery cell stack exposed from the module frame, a busbar that is connected to an electrode lead protruding from the battery cell stack via a first slot formed in the busbar frame, and a cooling fin that is located between battery cells adjacent to each other among the plurality of battery cells, wherein the busbar is connected to the cooling fin.