Cylindrical Battery Module Bus Bar Layout for Compact Thermal Isolation

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Solution Overview

Problem

Existing battery module designs face challenges in efficiently connecting cylindrical battery cells in various configurations while minimizing interconnect electrical resistance, mass, and volume, and in preventing thermal runaway propagation.

Innovation Solution

A battery module design featuring cylindrical battery cells with terminals oriented in specific planes, connected by conductive bus bars, and equipped with a thermal runaway protection (TRP) blanket and cooling plate to manage thermal events and optimize electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cylindrical battery cells are connected in various configurations using conventional methods, then electrical connectivity is achieved, but interconnect electrical resistance increases and manufacturing efficiency decreases

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The battery module is segmented into groups of cylindrical battery cells arranged in parallel configurations, with each group connected through standardized bus bar interfaces. This segmentation allows for modular assembly and reduces the complexity of interconnections while maintaining electrical connectivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bus bars are designed with universal connection capabilities that can accommodate different battery cell configurations (series, parallel, or combinations). The standardized connection interface enables the same bus bar design to serve multiple connection purposes, reducing manufacturing complexity and improving efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional battery module designs are used, then battery cells can be connected, but interconnect mass and volume increase

Engineering Contradiction:

Improveelectrical connectivityVSAvoidinterconnect mass

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The connection architecture transitions from traditional three-dimensional bulky connectors to flattened, planar bus bar configurations. By spreading connections across a two-dimensional plane rather than using volumetric connectors, the design reduces interconnect mass and volume while maintaining electrical connectivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Instead of using heavy, complex custom connectors for each connection point, the design employs simplified bus bar copies that can be replicated and standardized. These standardized bus bar units replace heavy conventional connectors, reducing overall interconnect mass while maintaining connection reliability.

Inventive Principle:

Principle #26Copying

3Volume of stationary object

If battery cells are closely packed to minimize volume, then space efficiency improves, but thermal runaway propagation risk increases

Engineering Contradiction:

Improvemodule volumeVSAvoidthermal runaway propagation

Core Design Contradiction:

Volume of stationary objectVSObject-affected harmful factors

Solution Approach 1:

Thermal barriers are introduced as intermediary elements between adjacent cylindrical battery cells. These barriers act as mediators that physically separate cells while allowing electrical connections to pass through, preventing direct thermal contact between cells. This intermediary layer blocks thermal runaway propagation pathways while maintaining the compact modular volume of the battery module.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Object-affected harmful factors

If thermal barriers are added between battery cells to prevent thermal runaway, then safety improves, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal runaway propagationVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The thermal barrier function is merged with the existing modular bus bar connection structure. Rather than adding separate thermal barrier components, the design integrates thermal blocking capabilities into the connection architecture itself, allowing a single manufacturing process to achieve both electrical connection and thermal isolation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The modular connection components are designed to serve multiple functions simultaneously: providing electrical connectivity, structural support, and thermal isolation. This multi-functionality reduces the total number of separate components needed, simplifying the manufacturing process while maintaining thermal safety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12463295B2Cylindrical cell-based parametric battery module for flexible assembly and packaging

Publication Date: 2025.11.04 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery module includes: a positive terminal disposed on an exterior of a housing of the battery module; a negative terminal disposed on the exterior of the housing of the battery module; groups of two or more cylindrical battery cells electrically connected in parallel; and electrically conductive bus bars that electrically connect the groups in series, that electrically connect positive terminals of the cylindrical battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the cylindrical battery cells of a second one of the groups with the negative terminal of the battery module.