Busbar Assembly Lead-Out Slit for Full Tab Contact
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Solution Overview
Problem
In existing battery assembly processes, the tabs of electrodes often fail to fully contact the conductive members in the busbar bracket, resulting in poor welding effects and unreliable electrical connections.
Innovation Solution
A busbar assembly with a tab lead-out slit that includes lead-out walls on both the conductive member and the busbar bracket, ensuring that tabs can be inserted to fully contact the conductive member, enhancing the reliability of the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are inserted into the busbar bracket using conventional methods, then the assembly process is simple, but the tabs cannot fully contact the conductive member resulting in poor welding effect and unreliable electrical connection
Solution Approach 1:
The busbar bracket is segmented into multiple components: the bracket body, the conductive member, and the lead-out walls. This segmentation allows each component to perform its specific function - the bracket provides structural support, the conductive member provides electrical conductivity, and the lead-out walls guide and constrain the tab to ensure full contact with the conductive member, thereby improving electrical connection reliability without excessive complexity
Solution Approach 2:
The lead-out walls act as intermediary elements between the tab and the conductive member. These walls guide the tab during insertion and ensure proper positioning, mediating the interaction between the tab and conductive member to achieve full contact and reliable electrical connection
2Manufacturing precision
If tabs are inserted into the busbar bracket, then the assembly process is straightforward, but the welding effect is poor due to incomplete contact between tabs and conductive member
Solution Approach 1:
The lead-out walls are pre-formed on the conductive member before tab insertion. These walls create a predetermined path and positioning structure that guides the tab into correct alignment with the conductive member, ensuring full contact is achieved automatically during the insertion process without requiring additional adjustment operations
Solution Approach 2:
The lead-out walls are specifically positioned at the insertion end of the conductive member where contact is needed. This local structural feature concentrates the guiding and positioning function at the critical contact zone, ensuring precise contact between tab and conductive member without complicating the entire structure
Data Source
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AI summary
The disclosure provides a busbar assembly (H) and a cell module. The busbar assembly (H) includes a busbar bracket (110), a conductive member (200), and a tab lead-out slit (310). The busbar bracket (110) has a first side (A) and a second side (B) facing away from each other. The conductive member (200) is arranged on the busbar bracket (110). The tab lead-out slit (310) extends from the first side (A) to the second side (B) and passes through the busbar bracket (110). The tab lead-out slit (310) has two opposite lead-out walls (301, 302), and at least one of the lead-out walls (301, 302) is formed on the conductive member (200).