Threaded Busbar Assembly for Compact Battery Module Fastening

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Solution Overview

Problem

Existing 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 a screw thread to fix the connection bolt directly, eliminating the need for a separate nut and reducing the thickness of the busbar while increasing the coupling force.

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 space requirements increase

Engineering Contradiction:

Improvecoupling forceVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The connection nut function is merged into the busbar frame by integrally forming the nut portion with the frame. This eliminates the need for a separate connection nut component while maintaining the coupling function, thereby reducing device complexity and component count while preserving the necessary coupling force through the integrated structure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar frame is given multiple functions: it provides structural support, houses the connection nut integrally, and serves as the mounting structure for the busbar. This multi-functionality reduces the overall component count while maintaining the coupling capability through the integrated nut portion

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a separate connection nut is used, then the coupling force is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvecoupling forceVSAvoidmanufacturing process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connection nut is merged with the busbar frame into a single integral structure. This eliminates the need for separate manufacturing of the nut and subsequent assembly operations, simplifying the manufacturing process while maintaining the required coupling force through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If the busbar thickness is increased to accommodate a separate nut, then the coupling force is improved, but the volume and space requirements increase

Engineering Contradiction:

Improvecoupling forceVSAvoidbusbar volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The connection nut is merged into the busbar frame structure, allowing the busbar to maintain its original thickness without additional space for a separate nut. The integral nut portion utilizes the existing frame structure, eliminating the need for increased busbar volume while preserving coupling force

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4109663B1Battery module including busbar having screw thread

Publication Date: 2025.07.09 LG ENERGY SOLUTION LTD

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AI summary

The present invention relates to a battery module including a busbar having a screw thread, and more particularly to a battery module including at least one busbar that electrically connects electrode leads protruding from an electrode assembly; a busbar frame connected to the busbar, the busbar being fixed to the busbar frame; a connection busbar connected to the at least one busbar; and a connection bolt connecting the busbar and the connection busbar together, wherein the busbar includes a screw thread configured to fix the connection bolt.