Insulated Inter-Busbar Structure for Thermal Runaway Short-Circuit Prevention

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional inter-busbars in battery packs are susceptible to exposure during thermal runaway, increasing the probability of internal short circuits due to discharge accumulation.

Innovation Solution

An inter-busbar unit with a conductive member embedded in partition walls and wrapped with an insulating material, ensuring that non-contacting areas are shielded, reducing the risk of internal short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the inter-busbar is exposed for electrical connection, then electrical connectivity is achieved, but the risk of internal short circuit increases due to discharge exposure during thermal runaway

Engineering Contradiction:

Improvesafety against internal short circuitVSAvoidexposure to discharge during thermal runaway

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an insulating material as an intermediary substance that coats the inter-busbar. This insulating layer acts as a mediator between the conductive inter-busbar and the harmful discharge environment, allowing electrical connectivity to be maintained while protecting against discharge-induced short circuits during thermal runaway events

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating material is applied selectively to specific portions of the inter-busbar, particularly to areas that are not required for electrical contact. This local application ensures that electrical connectivity is preserved at contact points while providing discharge protection to exposed portions of the inter-busbar

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If the inter-busbar is fully insulated, then protection against discharge is achieved, but electrical connectivity to module terminals is compromised

Engineering Contradiction:

Improveprotection from dischargeVSAvoidelectrical connectivity

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4685980A1Inter-bus bar unit, pack housing comprising same, battery pack comprising same, and method for manufacturing same

Publication Date: 2026.01.28 LG ENERGY SOLUTION LTD

Figure 1
Figure 2
Figure 3

AI summary

Disclosed are an inter-busbar unit including a conductive member electrically connected to a module terminal at a battery module, a first partition wall unit having a seating recess allowing the conductive member to be seated therein, and a second partition wall unit seated on the first partition wall unit, wherein opposite ends of the conductive member are exposed to different sides, a pack housing including the same, a battery pack including the same, and a method of manufacturing the same.