Busbar Extension Layout for Battery Electrolyte Leak Detection

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Solution Overview

Problem

Existing battery modules with electrolyte leakage detection systems are complex and reduce energy density, necessitating additional components for detection.

Innovation Solution

A battery module design featuring a busbar with an extension portion that protrudes towards the module case bottom to sense electrolyte leakage, eliminating the need for separate sensors or controllers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an electrolytic solution absorption member with conductor characteristics is added to detect leaks, then detection capability is improved, but device complexity increases

Engineering Contradiction:

Improveelectrolytic solution leakage detectionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The busbar is extended to protrude below the module case, merging the electrical connection function with the electrolytic solution detection function into a single component. This eliminates the need for separate absorption members and sensors, resolving the contradiction between detection capability and structural complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The extended busbar serves multiple functions: electrical connection between cells, structural support, and electrolytic solution leakage detection. By making the busbar multi-functional, the patent improves reliability without adding complex detection systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple additional members are provided for leak detection, then detection accuracy is improved, but energy density decreases

Engineering Contradiction:

Improveleakage detection accuracyVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The detection function is merged into the existing busbar structure, eliminating the need for additional members. This maintains energy density while achieving reliable leak detection through the busbar's inherent conductive properties

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar uses its own conductive characteristics to detect electrolytic solution leaks without requiring separate sensing components. The system leverages the busbar's inherent properties rather than adding specialized detection equipment that would reduce energy density

Inventive Principle:

Principle #25Self-service

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

Rapid detection of electrolyte leakage prevents short circuits and fire outbreaks without reducing energy density by utilizing the busbar's extension to monitor changes in electrical states.

Implementation Method 1

an electrolytic solution absorption member 10 attached to the outside of a cell to absorb an electrolytic solution that leaks from the cell, the electrolytic solution absorption member having the characteristics of a conductor as the result of absorbing the electrolytic solution

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12603330B2Battery module having electrolytic solution leakage detection function and battery pack including the same

Publication Date: 2026.04.14 LG ENERGY SOLUTION LTD

AI summary

A battery module has an electrolytic solution leakage detection function. The battery module has a busbar configured to detect an electrolytic solution leaked from a battery cell. The battery module can be used in a battery pack.