Threaded Busbar Connection for Compact Battery Module Assembly

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Solution Overview

Problem

Conventional battery modules require separate connection nuts and additional space for fixing busbars, which complicates manufacturing and reduces fixing force.

Innovation Solution

A battery module design that uses a busbar with integrated screw threads to connect busbars without a separate nut, enhancing coupling force and reducing space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a separate connection nut is used to fix the connection bolt, then the coupling force between busbar and connection busbar is improved, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:
Improvecoupling forceVSAvoidstructure complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The connection nut function is merged into the busbar frame by integrally forming the busbar frame and connection busbar, eliminating the need for separate connection nuts and reducing structural complexity while maintaining coupling force

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The busbar frame is given multiple functions: it serves as both the structural support frame and the connection nut, allowing the connection bolt to be fixed directly to the connection busbar without additional components

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Strength

If a separate connection nut is used, then the coupling force is improved, but the space requirement and manufacturing cost increase

Engineering Contradiction:
Improvecoupling forceVSAvoidspace requirement
Core Design Contradiction:
StrengthVSQuantity of substance

Solution Approach 1:

The connection nut and busbar frame are merged into a single integrated structure, eliminating the need for separate connection nuts and reducing space requirements in the battery module assembly

Inventive Principle:
Principle #5Merging (Combining)

3Strength

If different materials are used for connection nut and busbar frame, then the coupling strength is improved, but the manufacturing precision and production difficulty increase

Engineering Contradiction:
Improvecoupling strengthVSAvoidintegration precision
Core Design Contradiction:
StrengthVSManufacturing precision

Solution Approach 1:

The busbar frame and connection busbar are made of the same material and integrally formed, eliminating the need for multi-material joining processes and ensuring high manufacturing precision while maintaining coupling strength

Inventive Principle:
Principle #33Homogeneity

Data Source

PatentUS12500312B2Battery module including busbar having screw thread
Publication Date: 2025.12.16 LG ENERGY SOLUTION LTD
  • US12500312B2 patent drawing
  • US12500312B2 patent drawing
  • US12500312B2 patent drawing

AI summary

A battery module includes a busbar. The busbar that electrically connects electrode leads protruding from an electrode assembly to the busbar. The battery module also includes a busbar frame accommodating the busbar. The busbar is fixed to the busbar frame. The battery module also includes a connection busbar connected to the busbar and a connection bolt connecting the busbar and the connection busbar together. The busbar includes a first screw thread, and the connection bolt is fixed to the first screw thread.