Battery Module Bus Bar Assembly With Thermally Conductive Insulation
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Solution Overview
Problem
As energy density in battery modules increases, the temperature of the bus bar inside the module becomes excessively high, necessitating an effective solution to lower heat generation.
Innovation Solution
A battery module design incorporating a bus bar assembly with a thermal conduction unit made of a resin material containing thermally conductive fillers, such as boron nitride or aluminum oxide, to embed at least half of the bus bar, ensuring thermal conductivity of 2 W/mK or more, and providing electrical insulation with volume resistivity and surface resistance suitable for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If energy density of the battery module is increased, then the energy storage capacity is improved, but the temperature of the bus bar becomes excessively high
Solution Approach 1:
A thermal conduction unit is introduced as an intermediary component between the bus bar and the module case. This unit contains thermally conductive fillers (such as aluminum oxide, silicon carbide, or boron nitride) dispersed in a resin matrix, creating a thermal pathway that mediates heat transfer from the bus bar to the case, thereby resolving the temperature issue while maintaining high energy density configuration
Solution Approach 2:
The thermal conduction unit employs composite material structure combining resin matrix with thermally conductive filler particles. This composite approach achieves optimal balance between thermal conductivity (2 W/mK or more) and electrical insulation properties, allowing effective heat dissipation without compromising the electrical functionality of the bus bar assembly
2Temperature
If a thermal conduction unit is introduced to cool the bus bar, then heat dissipation is improved, but the device complexity increases
Solution Approach 1:
The thermal conduction unit merges multiple functions into a single integrated component: it provides thermal conduction to cool the bus bar, electrical insulation to prevent breakdown, and structural support for the bus bar assembly. By combining these functions in one element rather than separate components, the solution improves heat dissipation while minimizing increases in device complexity
3Temperature
If the bus bar is embedded in the thermal conduction unit, then heat dissipation is enhanced, but the electrical insulation requirement becomes more critical
Solution Approach 1:
The thermal conduction unit uses composite material formulation with resin matrix and thermally conductive fillers that provides both thermal conduction capability (2 W/mK or more) and sufficient electrical insulation properties (volume resistivity of 1×10^10 Ω·cm or more). This composite structure allows the bus bar to be embedded for effective cooling while the material itself provides the necessary electrical insulation barrier
Solution Approach 2:
The resin material undergoes curing transformation from liquid state to solid state, changing its physical parameters to achieve both thermal conduction and electrical insulation properties. The curing process modifies the material's molecular structure to provide dimensional stability and electrical insulation while maintaining thermal pathways through the conductive filler network
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 dissipates heat from the bus bar, minimizing temperature deviations and enhancing heat dissipation, while maintaining electrical insulation and preventing insulation breakdown.
Implementation Method 1
a thermal conduction unit for embedding the bus bar therein, wherein the thermal conduction unit is formed of a resin material containing a thermally conductive filler
Implementation Method 2
the solution effectively dissipates heat from the bus bar, minimizing temperature deviations and enhancing heat dissipation
Implementation Method 3
providing electrical insulation with volume resistivity and surface resistance suitable for safe operation
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked; a module case for accommodating the battery cell stack therein; and a bus bar assembly disposed between the module case and the battery cell stack and electrically connected to the battery cells. The bus bar assembly may include at least one bus bar and a thermal conduction unit for embedding the bus bar therein. The thermal conduction unit may be formed of a resin material containing a thermally conductive filler.