Battery Module Busbar Cover Layout for Moisture Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery modules face safety issues due to short circuits between busbars caused by moisture and electrolyte leakage, leading to potential fires.

Innovation Solution

A battery module design featuring insulating covers for busbars, including a first and second insulating cover to shield the space between busbars, coupled to the busbar frame, and a third insulating cover for terminal busbars, preventing direct contact and corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If busbars are arranged closely together to reduce space, then space utilization is improved, but short circuit risk increases due to moisture and electrolyte leakage

Engineering Contradiction:

Improvespace utilizationVSAvoidshort circuit risk

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

An insulating cover is introduced as an intermediary component between adjacent busbars. This cover physically separates the busbars while maintaining their close proximity arrangement, preventing direct contact that would cause short circuits. The insulating cover acts as a mediator that allows space-efficient busbar arrangement while eliminating the short circuit hazard.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating cover is pre-installed on busbars before assembly into the battery module. This preliminary protective measure prevents moisture and electrolyte from reaching the busbar surfaces, thereby preemptively counteracting the corrosion and short circuit risks that would otherwise occur in closely spaced arrangements.

Inventive Principle:

Principle #9Preliminary anti-action

2Reliability

If partition walls are added between busbars to prevent short circuits, then safety is improved, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of rigid partition walls, the invention uses thin insulating covers that wrap around individual busbars. These flexible covers provide effective electrical isolation and protection against moisture while occupying minimal space and adding little structural complexity. The thin-film approach achieves safety without the bulk and complexity of traditional partition wall structures.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If insulating covers are added to busbars, then short circuit prevention is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveshort circuit preventionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating covers are manufactured and pre-installed on busbars before the busbars are assembled into the battery module. This preliminary action allows for standardized mass production of covered busbars, simplifying the final assembly process. The pre-attachment approach reduces manufacturing complexity compared to installing insulation components during module assembly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12573697B2Battery module and battery pack including the same

Publication Date: 2026.03.10 LG ENERGY SOLUTION LTD

AI summary

A battery module including a battery cell stack, a busbar frame that is positioned in at least one end part of the battery cell stack, a housing that houses a cell block including the battery cell stack and the busbar frame, a pair of end plates that cover the front and rear surfaces of the cell block and are coupled to the housing, and an insulating cover that is positioned between the end plate and the battery cell stack. The insulating cover includes a first insulating cover and a second insulating cover. The first insulating cover covers the first busbar coupled to the busbar frame, and the second insulating cover covers the second busbar coupled to the busbar frame.