Battery Module Busbar Heat Path for Fast-Charging Thermal Stability
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Solution Overview
Problem
Conventional battery modules lack an effective cooling path for busbars, leading to difficulties in managing heat generated during high current and fast charging, which can result in thermal instability.
Innovation Solution
A battery module with a novel cooling structure that includes a first heat transfer member between the busbar and the battery cell stack, and additional heat transfer pads and members that contact the busbar and housing components, creating a direct and efficient heat transfer path to dissipate heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling structure is used for battery module, then device complexity is reduced, but heat dissipation capability deteriorates
Solution Approach 1:
The busbar is integrated with the heat transfer member to form a unified cooling structure. The busbar serves dual functions: electrical connection and heat dissipation. This merging eliminates the need for separate cooling components while effectively managing heat from the busbar, directly resolving the contradiction between simplified structure and improved heat dissipation.
Solution Approach 2:
The busbar is designed to perform multiple functions simultaneously: electrical current conduction, heat transfer from the battery cell, and structural support. By making the busbar multi-functional, the patent achieves effective heat dissipation without adding extra cooling components, thus maintaining structural simplicity while improving thermal management.
2Reliability
If busbar cooling path is not provided, then device complexity is minimized, but thermal stability deteriorates
Solution Approach 1:
The cooling path is created by merging the busbar with the heat transfer member, forming an integrated thermal management system. This unified structure provides a dedicated cooling path for the busbar without requiring separate cooling components, thereby improving thermal stability while maintaining structural simplicity.
Solution Approach 2:
The heat transfer member acts as an intermediary between the busbar and the cooling system. It facilitates heat transfer from the busbar to the coolant or heat sink, providing an effective cooling path while keeping the overall structure simple and avoiding direct complex cooling mechanisms.
3Productivity
If high current is used for fast charging, then charging speed is improved, but heat generation increases
Solution Approach 1:
The patent converts the harmful heat generated by high-current fast charging into a manageable thermal flow by integrating the busbar with the heat transfer member. The heat that would otherwise be a problem is channeled through the dedicated cooling path, allowing high-current charging to proceed while maintaining thermal control.
Solution Approach 2:
The integrated busbar-cooling structure ensures continuous heat dissipation during high-current charging operations. The cooling path operates continuously alongside the charging process, maintaining thermal stability throughout the fast charging cycle and enabling sustained high-current operation without thermal buildup.
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 novel cooling structure effectively transfers and discharges heat from the busbar, enhancing the stability and efficiency of the battery module by minimizing temperature rise during high current conditions such as fast charging.
Implementation Method 1
a first heat transfer member formed between the busbar and the battery cell stack... effectively transfers and discharges heat from the busbar
Data Source
AI summary
A battery module including a battery cell stack in which a plurality of battery cells are stacked, a housing that surrounds the battery cell stack, a busbar connected to an electrode lead protruding from the battery cell, and a first heat transfer member formed between the busbar and the battery cell stack, where the first heat transfer member is in contact with the housing.