Battery Cell Tab Guide Assembly for Thermal Runaway Venting
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Solution Overview
Problem
The assembly of battery cells is challenging due to the thin thickness of lead tab portions and slit holes, and thermal runaway can cause high-temperature gas to vent towards the busbar, compromising thermal stability.
Innovation Solution
A battery assembly design featuring a guide member with lead tab insertion holes and a busbar frame with through holes, facilitating easy assembly and directing high-temperature gas discharge during thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead tab portions are inserted directly into slit holes of the busbar, then electrical connection is achieved, but assembly difficulty increases due to thin thickness of both components
Solution Approach 1:
A guide member is introduced as an intermediary component between the lead tab portions and the busbar. The guide member includes insertion holes that receive the lead tab portions and guide them into proper alignment with the slit holes of the busbar, facilitating easier assembly despite the thin thickness of the components.
Solution Approach 2:
The guide member is positioned in advance between the busbar and the battery cells before the lead tab portions are inserted. This preliminary positioning establishes the correct spatial relationship and alignment, making the subsequent insertion process simpler and more reliable.
2Reliability
If thermal runaway occurs in battery cells, then high-temperature gas is vented toward the busbar, but thermal stability is compromised
Solution Approach 1:
The guide member serves as a thermal barrier between the battery cells and the busbar. During thermal runaway, the guide member blocks the direct path of high-temperature gas and particles from the battery cells to the busbar, preventing thermal propagation and protecting the electrical connection components.
Solution Approach 2:
The guide member divides the space between the battery cells and the busbar, creating separate zones. This segmentation prevents the direct transmission of thermal energy and isolates the busbar from the harmful effects of thermal runaway events.
3Ease of operation
If insulating cover is removed from battery assembly, then accessibility is improved, but insulating effect may be compromised
Solution Approach 1:
The guide member performs multiple functions: it facilitates assembly by guiding the lead tab portions, provides thermal protection during thermal runaway, and maintains electrical insulation between the battery cells and the busbar. This multi-functionality eliminates the need for a separate insulating cover while preserving all necessary protective functions.
Data Source
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AI summary
The present disclosure relates to a battery assembly and a method for assembling the same including: a plurality of battery cells (110), each including a lead tab portion (111) protruding in a first direction, stacked in a second direction; a busbar (54) electrically connected to the plurality of battery cells; and a guide member (51) positioned between the busbar and the plurality of battery cells, and including a plurality of lead tab insertion holes into which each lead tab portion of the plurality of battery cells is inserted along the first direction.