Integrated Busbar End Plate for Cooling High-Voltage Battery Modules

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Solution Overview

Problem

Existing battery cell designs face challenges in effectively connecting cell tabs and busbars to cooling systems due to installation space constraints, leading to localized heating and difficulty in integrating them into cooling systems, which affects thermal management and performance.

Innovation Solution

Integrate busbars into an electrically insulating end plate of a high-voltage battery module, with electrical and thermal contacting surfaces, allowing for direct thermal connection to a cooling plate while maintaining electrical insulation, and use thermally conductive paste to enhance heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If cell tabs are connected to cooling systems using conventional methods, then cooling capacity is provided to battery cells, but installation space is insufficient and localized heating occurs at cell tabs

Engineering Contradiction:

Improvecooling capacityVSAvoidinstallation space

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The busbar and cooling system connection elements are merged into a single integrated component. The busbar serves dual functions: electrical connection to cell tabs and thermal connection to cooling plates, eliminating the need for separate cooling connections at cell tab locations and resolving installation space constraints

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar is designed as a multi-functional component that simultaneously provides electrical conductivity (connecting cell tabs to external circuits) and thermal conductivity (transferring heat from cell tabs to cooling plates). This universal component solves both electrical and thermal management requirements in a single element

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If busbars are thermally connected to cooling plates, then heat dissipation is improved, but electrical insulation between busbars and cooling system must be maintained

Engineering Contradiction:

Improveheat dissipationVSAvoidelectrical insulation requirements

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The busbar exhibits different material properties at different locations: high electrical conductivity at the electrical contacting surface for current flow, and high thermal conductivity at the thermal contacting surface for heat transfer to cooling plates. This spatial differentiation of material properties allows simultaneous thermal management and electrical insulation without additional complex components

Inventive Principle:

Principle #3Local quality

3Reliability

If cell tabs are welded to busbars, then electrical connection is established, but assembly complexity increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The busbar is pre-integrated into the end plate during end plate manufacturing, with thermal contacting surfaces and electrical contacting surfaces prepared in advance. Cell tabs are then simply welded to the pre-positioned busbar, eliminating complex assembly steps and reducing overall manufacturing complexity while maintaining reliable electrical connections

Inventive Principle:

Principle #10Preliminary action

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

Improves thermal management by enabling efficient heat dissipation from busbars and cell tabs, enhancing rapid charging and discharging capabilities, and improving mechanical stability and assembly processes.

Implementation Method 1

The at least one thermal contacting surface of the at least one busbar is thermally connected to the at least one longitudinal side of the module housing connected to the cooling plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

At least one longitudinal side of the module housing is connected to a cooling plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a direct flow of a dielectric fluid around the battery cells

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12542333B2High-voltage battery module and method for producing a coolable high-voltage battery module with busbar integration

Publication Date: 2026.02.03 DR ING H C F PORSCHE AG

AI summary

A high-voltage battery module includes a module housing, a cell stack which includes a plurality of cells having respective cell terminals, and an end plate which is disposed on at least one end face of the module housing and in which the at least one busbar is integrated. At least one longitudinal side of the module housing is connected to a cooling plate. The end plate is made of an electrically insulating material. The at least one busbar includes at least one electrical contacting surface toward an outer side of the end plate and at least one thermal contacting surface toward at least one edge of the end plate. The at least one thermal contacting surface of the at least one busbar is thermally connected to the at least one longitudinal side of the module housing connected to the cooling plate.