Flexible Busbar Layout for Battery Module Swelling Compensation

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Solution Overview

Problem

Existing busbars for battery modules are mechanically simple and contribute to increased module height, failing to address mechanical stress and dimensional changes due to cell swelling, while also limiting compact design possibilities.

Innovation Solution

A busbar design with a planar body portion and non-parallel legs that extend from the body portion, allowing the body portion to be positioned next to cell terminals, reducing mechanical stress and enabling a compact size by utilizing flexible legs that can pivot and deform to accommodate dimensional changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If simple bar-shaped aluminum strips are used for busbars, then manufacturing is easier and device complexity is reduced, but the battery module height increases and mechanical stress compensation capability is lost

Engineering Contradiction:

Improvebusbar structure complexityVSAvoidbattery module height

Core Design Contradiction:

Device complexityVSLength of stationary object

Solution Approach 1:

The busbar is segmented into a body portion and multiple legs that can independently deform. This segmentation allows each leg to flex separately to accommodate cell swelling while maintaining overall structural integrity, resolving the contradiction between structural simplicity and mechanical adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The busbar transitions from a rigid simple bar shape to a dynamic structure with flexible legs that can pivot and deform. The legs are designed with controlled flexibility to dynamically adapt to cell dimensional changes during battery operation, reducing module height while compensating for mechanical stress.

Inventive Principle:

Principle #15Dynamics

2Reliability

If complex three-dimensional busbar shapes are used, then mechanical stress compensation and cell swelling compensation are improved, but device complexity increases and manufacturing becomes more difficult

Engineering Contradiction:

Improvemechanical stress compensationVSAvoidbusbar structural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Different parts of the busbar have different mechanical properties - the body portion provides structural stability while the legs provide flexibility for stress compensation. This local differentiation of mechanical properties allows the busbar to simultaneously maintain structural integrity and compensate for cell swelling without requiring complex overall geometry.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The busbar design changes the flexibility parameter locally at the legs while maintaining rigidity in the body portion. By controlling the thickness, length, and material properties of specific segments, the busbar achieves optimal balance between mechanical strength and flexibility for stress compensation.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If rigid busbar structures are used, then structural stability is maintained, but adaptability to cell dimensional changes and swelling compensation is reduced

Engineering Contradiction:

Improvebusbar structural stabilityVSAvoidadaptability to cell swelling

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The busbar is divided into a stable body portion and flexible legs, allowing different segments to fulfill different functions. The body maintains structural stability for electrical connectivity, while the segmented legs provide adaptability to accommodate cell swelling through independent deformation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The busbar incorporates dynamic elements in the form of flexible legs that can pivot and deform in response to cell dimensional changes. This dynamic capability allows the structure to adapt to swelling while the rigid body portion maintains overall structural stability.

Inventive Principle:

Principle #15Dynamics

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 busbar design reduces mechanical stress, enhances flexibility, and compensates for cell swelling, thereby improving stability and enabling a more compact battery module configuration.

Implementation Method 1

utilizing flexible legs that can pivot and deform to accommodate dimensional changes

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12463294B2Busbar for a battery module and battery module

Publication Date: 2025.11.04 SAMSUNG SDI CO LTD

AI summary

A busbar for a battery module is provided. The battery module includes a plurality of aligned battery cells, and the busbar includes: a busbar body portion extending in an extension direction and a plurality of legs extending from the busbar body portion in a direction non-parallel to the extension direction of the busbar body portion. The busbar body portion have a length to connect cell terminals of a plurality of the battery cells of the battery module, and the legs are configured to electrically connect the busbar body portion and the cell terminals of the battery cells of the battery module to each other.