Bus Bar Assembly Insulation Against Condensation Short Circuits

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Solution Overview

Problem

Conventional battery modules are susceptible to short circuits due to dew condensation, which can occur when exposed to environmental changes, posing a risk to the sensing bus bars.

Innovation Solution

A battery module design that includes a bus bar assembly with short-circuit prevention members made of insulating materials, such as rubber, which surround the ends of the sensing bus bars to prevent contact with condensed water.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery module design is used, then manufacturing simplicity is maintained, but short circuit risk increases due to dew condensation

Engineering Contradiction:

Improveshort circuit preventionVSAvoidbus bar assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An insulating member is introduced as an intermediary component between the sensing bus bar and the condensed water. This insulating member includes a through hole that allows the sensing bus bar to pass through while providing electrical insulation, thereby preventing short circuits without requiring complex redesign of the entire bus bar assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bus bar assembly is segmented into functional components: the sensing bus bar for electrical connection, the insulating member for protection, and the through hole for structural integration. This segmentation allows each component to perform its specific function independently while maintaining overall system reliability

Inventive Principle:

Principle #1Segmentation

2Reliability

If insulation measures are added to prevent short circuits, then reliability improves, but manufacturing complexity increases

Engineering Contradiction:

Improvesensing bus bar protectionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating member is merged with the existing bus bar assembly structure, where the through hole is formed as an integral part of the insulating member. This merging allows the insulation function to be added without requiring separate assembly steps or additional components, thereby maintaining ease of manufacture while improving reliability

Inventive Principle:

Principle #5Merging (Combining)

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 prevents short circuits between sensing bus bars when dew condensation occurs, ensuring the reliability and safety of the battery module, pack, and vehicle systems.

Implementation Method 1

short-circuit prevention members made of insulating materials, such as rubber, which surround the ends of the sensing bus bars to prevent contact with condensed water

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS12278396B2Battery module, battery pack comprising battery module, and vehicle

Publication Date: 2025.04.15 LG ENERGY SOLUTION LTD

AI summary

A battery module includes battery cells, a module case configured to accommodate the battery cells, and a bus bar assembly electrically connected to electrode leads of the battery cells. The bus bar assembly includes a bus bar frame disposed on at least one side of the battery cells, lead slots provided so that electrode leads of the battery cells pass therethrough, sensing bus bars connected to the electrode leads of the battery cells, and short-circuit prevention members configured to surround at least one end of the sensing bus bars.