Battery Module Busbar Insulation Against Welding Debris Shorts

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Solution Overview

Problem

Foreign matter generated during the welding process in battery module manufacturing degrades stability and poses a fire risk due to potential short circuits between battery cells.

Innovation Solution

A battery module design incorporating a busbar holder, insulating parts, and penetration prevention parts that prevent foreign matter from entering gaps between battery cells, ensuring electrical isolation and preventing short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a welding process is used to bond busbars and electrodes of battery cells, then electrical connection between battery cells is achieved, but foreign matter is generated that degrades stability and poses fire risk

Engineering Contradiction:

Improvestability of battery cellsVSAvoidforeign matter generated in welding process

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes the harmful byproducts (foreign matter) generated during the welding process through suction means, preventing them from accumulating and causing instability or fire hazards in the battery module

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces suction means as an intermediary component between the welding process and the battery cells to capture and remove foreign matter, acting as a mediator that prevents harmful substances from reaching the battery cells

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If foreign matter is introduced between adjacent battery cells, then welding process can be completed, but short circuits occur and fire risk increases

Engineering Contradiction:

Improvewelding process completionVSAvoidshort circuit and fire risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful foreign matter generated during welding into a removable byproduct by using suction means to actively extract it, transforming the welding process from a source of contamination to a controlled process where contaminants are systematically removed

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies preliminary anti-action by positioning suction means to prevent foreign matter from reaching critical areas between battery cells before it can cause short circuits or fire hazards, countering the potential harm before it occurs

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentEP4679591A1Battery module

Publication Date: 2026.01.14 SAMSUNG SDI CO LTD

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AI summary

A battery module includes a housing body, a plurality of battery cells disposed in the housing body and including terminal parts, a busbar connected to the terminal parts to electrically connect the plurality of battery cells, a busbar holder between the busbar and the plurality of battery cells, the busbar holder supporting the busbar, an insulating part between adjacent battery cells of the plurality of battery cells to insulate the adjacent battery cells from each other, and a penetration prevention part which prevents foreign matter from being introduced between the plurality of battery cells.