Bus-Bar Coupled Battery Cell Barrier for Cascading Explosion Prevention
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Solution Overview
Problem
Battery cells can explode due to heat or external impacts, leading to consecutive explosions of adjacent cells, and there is a need for a solution to prevent the spread of flames and gases generated by such explosions.
Innovation Solution
A battery cell assembly with a barrier interposed between cells, coupled to a bus-bar assembly, featuring a bus-bar frame, support tabs, and a barrier plate to contain and discharge gases, and a fastening mechanism to secure the barrier, using materials like mica, metal, or resin to prevent spread and enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier is installed between battery cells to prevent consecutive explosions, then safety is improved, but device complexity increases
Solution Approach 1:
The barrier is integrated with the bus bar assembly, combining the electrical connection function and the safety barrier function into a single structural unit. The barrier plate is positioned between battery cells while the bus bar extends through it, merging two components (barrier and bus bar) into one integrated assembly that reduces overall device complexity.
Solution Approach 2:
The bus bar assembly serves multiple functions: it provides electrical connection between cells and simultaneously acts as a structural support for the barrier. The barrier plate not only prevents flame and gas propagation but also maintains spatial separation between cells. This multi-functionality reduces the number of separate components needed.
2Quantity of substance
If battery cell capacity is increased to improve total battery pack capacity, then energy storage is improved, but the risk of consecutive explosions increases
Solution Approach 1:
The barrier plate divides the battery pack into separate compartments between adjacent battery cells. This segmentation prevents flames and gases from one cell from propagating to neighboring cells, effectively isolating potential explosion events. The barrier creates physical segments that limit the spread of harmful effects while allowing each cell to maintain high capacity.
3Reliability
If a barrier is added between battery cells to contain gases, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The barrier plate is integrated with the bus bar assembly during manufacturing, combining what would otherwise be separate manufacturing steps. The bus bar extends through the barrier plate, and they are formed as a unified structure, reducing the number of assembly operations required and simplifying the manufacturing process.
Data Source
AI summary
A battery cell assembly includes a plurality of battery cells, a bus-bar assembly to which electrode leads of the plurality of battery cells are coupled, and a barrier interposed between the plurality of battery cells and coupled to the bus-bar assembly.