Battery Module Busbar-Lead Cooling With Conductive Sheet

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Solution Overview

Problem

Existing battery modules, particularly high-performance ones, face challenges in effectively dissipating heat generated from electrode leads, which can lead to degradation and performance issues.

Innovation Solution

A battery module design incorporating a conductive sheet facing the busbar with an interposed lead region, an end cap member with insulation, and heat transfer members made of different materials to enhance heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If high-performance battery cells are used to increase power output, then power performance is improved, but heat generation from electrode leads increases

Engineering Contradiction:
Improvepower outputVSAvoidheat generation
Core Design Contradiction:
PowerVSObject-generated harmful factors

Solution Approach 1:

A conductive sheet is introduced as an intermediary component between the electrode lead and the cooling plate. This conductive sheet has higher thermal conductivity than the lead material, serving as a heat transfer bridge that efficiently conducts heat from the lead to the cooling plate, thereby resolving the heat dissipation problem caused by high power output

Inventive Principle:
Principle #24Intermediary (Mediator)

2Device complexity

If conventional heat dissipation structures are used, then structural simplicity is maintained, but heat dissipation effectiveness is insufficient

Engineering Contradiction:
Improvestructural simplicityVSAvoidheat dissipation effectiveness
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

Instead of uniformly increasing the complexity of the entire heat dissipation system, the invention applies local quality enhancement by selectively placing a conductive sheet only at the critical heat generation point (the electrode lead connection area). This localized approach improves heat dissipation effectiveness precisely where needed without significantly increasing overall structural complexity

Inventive Principle:
Principle #3Local quality

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

Effectively dissipates heat from the electrode leads, preventing degradation and improving module performance by maintaining optimal temperature ranges.

Implementation Method 1

a first conductive sheet provided to face the busbar and may contain a thermally conductive material

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a cooling plate provided to face the busbar with the lead region interposed therebetween

Methodology Applied
Scientific EffectConvection: Convection

Implementation Method 3

the cooling plate is configured to cover an entire region in which the lead region is attached to the busbar

Methodology Applied
Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20250385333A1Battery module
Publication Date: 2025.12.18 HYUNDAI MOTOR CO LTD
  • US20250385333A1 patent drawing
  • US20250385333A1 patent drawing
  • US20250385333A1 patent drawing

AI summary

Disclosed is a battery module including a battery stack including a plurality of battery cells stacked. The battery module further includes a pad member, a holder member provided at a side of the battery stack, a busbar assembled to the holder member and electrically connected to the battery stack, and a first conductive sheet provided to face the busbar and containing a thermally conductive material. The plurality of battery cells each have a lead region tightly attached to the busbar. The first conductive sheet is provided to face the busbar with the lead region interposed therebetween, and the first conductive sheet is tightly attached to the lead region or the busbar.