Inter-Module Busbar Venting Structure for Thermal Runaway Delay

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Solution Overview

Problem

Conventional busbars fail to effectively manage thermal runaway propagation in battery packs, leading to explosions due to high pressure and fire spread, as they lack mechanisms to guide venting gas and prevent cover member melting.

Innovation Solution

An inter-module busbar with a metal plate and cover member, featuring through-holes and thermoplastic closure members, guides venting gas away from neighboring modules, preventing pressure buildup and maintaining structural integrity during thermal events.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional busbar assembly is used to electrically connect battery modules, then electrical connection is achieved, but pressure relief mechanism is absent leading to explosion risk from venting gas

Engineering Contradiction:

Improvesafety against explosionVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The busbar body is designed to perform multiple functions: electrical connection and pressure relief. By integrating vent channels directly into the busbar structure, the same component serves both as an electrical conductor and a pressure relief device, eliminating the need for separate pressure relief mechanisms while enhancing safety

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The busbar incorporates localized vent channels at specific positions on its body. These channels are strategically placed to allow venting gas to escape at controlled locations, providing pressure relief exactly where needed without compromising the overall electrical connection function

Inventive Principle:

Principle #3Local quality

2Reliability

If a cover member is used to wrap the busbar, then structural protection is provided, but the cover member melts at high temperature causing thermal runaway propagation

Engineering Contradiction:

Improveresistance to thermal runaway propagationVSAvoidmelting resistance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The cover member is constructed from composite materials that combine high-temperature resistance with mechanical protection properties. This composite structure allows the cover to withstand the extreme temperatures generated during thermal runaway events without melting, thereby preventing fire and venting gas from spreading to adjacent battery modules

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The design accepts that thermal runaway will generate high temperatures and venting gas, but converts this harmful thermal energy into a controlled venting process. The cover member's high-temperature resistance ensures that instead of melting and spreading fire, the thermal energy is channeled through controlled vent channels, transforming a potential propagation hazard into a contained venting mechanism

Inventive Principle:

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

3Object-affected harmful factors

If venting gas is not guided away from neighboring modules, then pressure buildup occurs causing explosion, but adding guidance mechanism increases device complexity

Engineering Contradiction:

Improveimpact of venting gas on neighboring modulesVSAvoidstructural complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The busbar is designed as a multi-functional component that simultaneously provides electrical connection and venting gas guidance. The integrated vent channels in the busbar body guide venting gas away from neighboring battery modules without requiring separate guidance structures, reducing overall device complexity while effectively managing the harmful effects of venting gas

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The inter-module busbar effectively delays thermal runaway propagation by guiding venting gas and preventing cover member melting, thereby inhibiting explosions and maintaining the battery pack's integrity.

Implementation Method 1

a first closure member (300) is configured to be inserted into the first through-hole (110) of the metal plate (100)... when fire and venting gas occur in a battery cell... the first closure member (300) may include a thermoplastic material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

guiding the movement of venting gas generated by fire in a battery cell to a nearby space, thereby delaying and inhibiting explosion due to high pressure

Methodology Applied

Scientific EffectPressure gradient driven flow: Pressure Gradient

Data Source

PatentEP4421964B1Intermodule bus bar capable of delaying thermal runaway transition, and battery pack comprising same

Publication Date: 2026.03.18 LG ENERGY SOLUTION LTD

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AI summary

The present invention relates to an inter-module busbar capable of delaying thermal runaway propagation and a battery pack including the same, and more particularly to an inter-module busbar capable of delaying thermal runaway propagation, the inter-module busbar including a metal plate for electrical connection and a cover member configured to partially encompass the metal plate, wherein the metal plate has at least one first through-hole formed therein in a longitudinal direction, and wherein a first closure member is configured to be inserted into the first through-hole of the metal plate, and a battery pack including the same.