Battery Module Thermal Foam Structure for Lighter Cell Cooling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery modules face challenges in balancing fixability and heat transfer performance while minimizing the use of thermal conductive resin, leading to increased weight and potential overheating issues.

Innovation Solution

A battery module design incorporating a thermal conductive adhesive and heat dissipation foam, with a graphite heat dissipation sheet, to enhance fixability and heat transfer while reducing the amount of thermal conductive resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the amount of thermal conductive resin is reduced to decrease weight, then weight is reduced, but fixability and heat transfer rate of secondary battery cells deteriorate

Engineering Contradiction:

Improveweight of battery moduleVSAvoidfixability and heat transfer rate

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses a composite material consisting of thermal conductive resin mixed with metal particles (such as aluminum or copper particles). This composite material provides both the weight reduction benefit of reduced resin quantity and the heat transfer performance enhancement from the high thermal conductivity metal particles, resolving the contradiction between weight reduction and heat transfer performance maintenance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If thermal conductive resin is used to fix secondary battery cells and transfer heat, then fixability and heat transfer are improved, but the weight of the battery module increases

Engineering Contradiction:

Improvefixability and heat transfer performanceVSAvoidweight of battery module

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies thermal conductive resin selectively at specific locations where heat transfer is most critical, such as at the bottom of the battery module and between adjacent battery cells. By concentrating the resin in these key areas rather than uniformly throughout, the patent maintains effective heat transfer and fixability while minimizing the total amount of resin used, thus reducing overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent incorporates metal particles (aluminum, copper, or their alloys) into the thermal conductive resin to create a composite material with enhanced thermal conductivity. This allows the use of smaller amounts of resin while achieving the same or better heat transfer performance, thereby reducing the overall weight of the battery module.

Inventive Principle:

Principle #40Composite materials

3Power

If a plurality of pouch-type secondary batteries are stacked to form a battery module, then power and capacity are increased, but heat generation increases and cooling becomes more difficult

Engineering Contradiction:

Improvepower and capacity of battery moduleVSAvoidtemperature increase and heat management

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent introduces thermal conductive resin as an intermediary material between the pouch-type secondary batteries and the cooling structure (such as the aluminum plate at the bottom). This intermediary material ensures efficient heat transfer from the battery cells to the cooling structure, enabling effective heat management in high-power, high-capacity battery modules with multiple stacked cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The use of composite materials containing metal particles in the thermal conductive resin enhances the thermal conductivity pathway, allowing heat to be efficiently conducted away from the densely packed battery cells. This enables the battery module to achieve high power and capacity while maintaining effective cooling through the stacked configuration.

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 design achieves improved stability and cooling performance with reduced weight by utilizing a lighter heat dissipation foam and adhesive combination, effectively managing heat transfer and fixability.

Implementation Method 1

a thermal conductive adhesive provided in a space between a lower end of the cell stack and a bottom surface of the module housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a heat dissipation foam having a foam with a predetermined volume and a heat dissipation sheet configured to surround the foam

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 3

a heat dissipation sheet configured to surround the foam

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12548815B2Battery module

Publication Date: 2026.02.10 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a cell stack having a plurality of secondary batteries arranged along one direction; a module housing configured to accommodate the cell stack therein; a thermal conductive adhesive provided in a space between a lower end of the cell stack and a bottom surface of the module housing; and a heat dissipation foam having a foam structure with a predetermined volume and a heat dissipation sheet configured to surround the foam. The heat dissipation foam is disposed in the space between the lower end of the cell stack and the bottom surface of the module housing so as to be surrounded by the thermal conductive adhesive.