Battery Cell Bundle with Barrier Walls and Internal Busbars
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Solution Overview
Problem
Existing battery cell bundles face challenges in efficiently connecting battery cells in series and parallel configurations, managing thermal runaway, and directing gas discharge, which complicates the manufacturing process and increases the risk of heat and flame spread.
Innovation Solution
A battery cell bundle design featuring a support member with barrier walls, internal busbars, and venting members that allow for simplified electrical connectivity, stable gas discharge, and enhanced thermal management, including a sensing unit for monitoring electrical states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional battery cell connection structures are used, then electrical connectivity between battery cells can be achieved, but the connection structure becomes complex and manufacturing becomes difficult
Solution Approach 1:
The connection structure is segmented into modular components: support members with integrated barrier walls, internal busbars with external busbars, and standardized fastening portions. This segmentation allows each component to be manufactured independently and assembled systematically, reducing overall manufacturing complexity while maintaining electrical connectivity functionality.
Solution Approach 2:
The support member serves multiple functions simultaneously: it provides structural support for battery cells, contains integrated barrier walls for thermal management, and incorporates fastening portions for securing busbars. This multi-functionality reduces the number of separate components needed, simplifying the overall connection structure and easing manufacturing.
2Quantity of substance
If battery cells are closely arranged to increase energy density, then space utilization improves, but thermal runaway risk and heat spread increase
Solution Approach 1:
Barrier walls are strategically positioned at specific locations between battery cells where thermal isolation is most critical. This localized approach provides thermal protection exactly where needed while minimizing the space consumed by safety structures, allowing closely arranged battery cells to maintain both high energy density and reduced thermal runaway risk.
Solution Approach 2:
The barrier wall acts as an intermediary structure between adjacent battery cells, providing thermal isolation and preventing direct heat transfer. This mediator allows battery cells to be closely arranged for high energy density while the barrier wall intervenes to block thermal runaway propagation.
3Reliability
If gas discharge paths are not properly designed, then manufacturing is simpler, but gas accumulation leads to increased pressure and safety risks
Solution Approach 1:
The venting member is merged with the support member structure, integrating gas discharge functionality into the existing structural framework. This combination provides effective gas venting pathways without requiring separate complex venting systems, maintaining safety while avoiding excessive structural complexity.
4Productivity
If internal busbar configuration is simplified, then manufacturing efficiency improves, but electrical connectivity and stability may be compromised
Solution Approach 1:
The internal busbar is pre-configured with integrated fastening portions and connection interfaces during manufacturing. This preliminary preparation allows for quick and reliable assembly with battery cells and external busbars, maintaining high electrical connectivity reliability while improving manufacturing efficiency through reduced assembly steps.
Data Source
AI summary
A battery cell bundle comprises a support member including a barrier wall including first and second sides extending from an end of the support member; a plurality of first battery cells disposed on the first side of the barrier wall and a plurality of second battery cells disposed on the second side of the barrier wall; and an internal busbar to electrically connect the plurality of battery cells to each other, wherein the internal busbar includes a first busbar to electrically connect the plurality of first battery cells to each other, and a second busbar to electrically connect the plurality of second battery cells to each other, and wherein a portion of the first busbar is electrically connected to a portion of the second busbar.