Apparatus and method for assembling a battery module

Abstract

The present invention relates to an apparatus and method for assembling a battery module, the apparatus configured for assembling a battery stack including a plurality of stacked battery cells and a conductive block having bus bars electrically connected to battery leads of the plurality of battery cells, the apparatus including: a jig base including a rear base and a front base integrally formed with the rear base; a bending knife slidably disposed in the jig base, the bending knife having a front surface to selectively contact at least one battery lead and being elastically supported by a first leaf spring formed on a first side surface of the rear base; a jig plate disposed outside the jig base and configured to slide in a predetermined direction along the jig base; and a bending link pivotably engaged with a front end portion of the jig plate and configured to rotate a predetermined angle with respect to the jig plate when pressing the at least one battery lead.

Description

Technical Field

[0001] This invention relates to an apparatus and method for assembling battery modules. Background Technology

[0002] Battery packs used in hybrid or electric vehicles can be formed by combining multiple modular components in which multiple battery cells are stacked.

[0003] Typically, in a battery pack, two end plates on either side of the support module assembly are fixed to the substrate to encapsulate the module assembly.

[0004] Modular components can be formed by combining multiple battery cells connected in series or in parallel.

[0005] Currently, modular components achieve the required capacity by assembling the required number of battery cells. To achieve electrical connections between battery cells, negative or positive leads are bent, and each bent battery lead is soldered together.

[0006] Traditional assembly processes involve bending each battery lead of the battery cell and welding the battery leads separately. That is, a semi-assembled module is formed through the bending process, and then the battery leads are welded onto the semi-assembled module, making the entire process relatively complex.

[0007] The information disclosed in the background section of this invention is only intended to enhance the understanding of the overall background of this invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0008] Various aspects of the present invention aim to provide an apparatus and method for assembling a battery module, for simultaneously handling the bending of battery leads and soldering the battery leads to a busbar.

[0009] An apparatus for assembling battery modules, including battery stacks and conductive blocks, the battery stack comprising a plurality of stacked battery cells, the conductive blocks having busbars electrically connected to battery leads of the plurality of battery cells, the apparatus comprising: a clamping base including a rear base and a front base integrally formed therefrom; a bending blade slidably disposed in the clamping base, the bending blade having a front surface for selectively contacting at least one battery lead and being elastically supported by a first leaf spring formed on a first side of the rear base; a clamping plate disposed outside the clamping base and configured to slide back and forth along the clamping base; and a bending link pivotally engaged with a front end of the clamping plate and configured to rotate perpendicular to the clamping plate when pressure is applied to at least one battery lead.

[0010] The front surface of the curved blade is shaped to be inclined to form a bevel.

[0011] The curved blade is configured to press the edge of at least one battery lead against the busbar by means of an inclined plane, which is elastically supported by a first leaf spring.

[0012] The clamp plate is joined to the mating grooves on both sides of the front base by a mating part that extends integrally from both sides of the plate-shaped body corresponding to the clamp base and bends on both sides.

[0013] The clamp plate is configured to pass through a mounting hole formed on the rear base via a protrusion, which is integrally formed with and protrudes from the rear central portion of the body.

[0014] The clamp plate is elastically supported by a second leaf spring formed on the second side of the rear base via a support portion, which extends integrally from the two rear ends of the main body and bends at the two rear ends.

[0015] The bending link can pivotally engage with the front end of the clamping plate and form a hollow space relative to the front end of the clamping plate.

[0016] When pressure is applied to the battery leads, the bending link is configured to rotate perpendicular to the clamp plate by contacting the battery leads, thereby using a laser beam passing through the hollow space to weld at least one battery lead to the busbar.

[0017] A slot is formed through the rear base between the clamping plate and the bending blade. When the bending link is perpendicular to the clamping plate, the hollow space and the slot of the clamping base are aligned with the battery stack.

[0018] The bending link includes a return spring mounted on the hinge portion between the bending link and the clamping plate.

[0019] In the apparatus and method for assembling battery modules according to various exemplary embodiments of the present invention, at least one battery lead of the battery cell is bent toward the busbar while being forced into close contact with the busbar, thereby reducing the cycle time of the welding process.

[0020] The apparatus and method for assembling battery modules according to various exemplary embodiments of the present invention can simplify the entire process, reduce investment costs and increase productivity.

[0021] The methods and apparatus of the present invention also have other features and advantages, which will be apparent from or set forth in more detail in conjunction with the accompanying drawings and the following detailed description, which together serve to explain the particular principles of the invention. Attached Figure Description

[0022] Figure 1 The invention illustrates the assembly of a battery module using an apparatus for assembling a battery module according to various exemplary embodiments of the invention.

[0023] Figure 2 This is a schematic diagram showing a first side of an apparatus for assembling a battery module according to various exemplary embodiments of the present invention;

[0024] Figure 3 This is a schematic diagram of the other side of an apparatus for assembling a battery module according to various exemplary embodiments of the present invention;

[0025] Figure 4 This is a view illustrating a method for assembling a battery module according to various exemplary embodiments of the present invention.

[0026] It should be understood that the accompanying drawings are not necessarily drawn to scale, but rather present a simplified representation of various features illustrating the basic principles of the invention. Specific design features of the invention, such as specific dimensions, orientations, positions, and shapes, as disclosed herein, will be determined in part by the particular intended application and environment of use.

[0027] In the accompanying drawings, throughout the multiple figures, reference numerals denote the same or equivalent parts of the invention. Detailed Implementation

[0028] Reference will now be made in detail to various embodiments of the invention, examples of which are shown in the accompanying drawings and described below. While the invention will be described in conjunction with exemplary embodiments thereof, it should be understood that this description is not intended to limit the invention to these exemplary embodiments. Rather, the invention is intended to cover not only these exemplary embodiments thereof, but also various alternatives, modifications, equivalents and other embodiments that may be included within the spirit and scope of the invention as defined by the appended claims.

[0029] Exemplary embodiments of the present application will be described more fully below with reference to the accompanying drawings, in which exemplary embodiments of the invention are illustrated. Those skilled in the art will recognize that the described embodiments can be modified in various ways without departing from the spirit or scope of the invention.

[0030] To clarify the invention, parts irrelevant to the description will be omitted, and the same reference numerals will denote the same elements or equivalents throughout the specification.

[0031] Figure 1 The invention illustrates the assembly of a battery module using an apparatus for assembling a battery module according to various exemplary embodiments of the invention.

[0032] Reference Figure 1According to various exemplary embodiments of the present invention, the apparatus 30 for assembling battery modules is used to assemble a battery stack 10 and a conductive block 20, the battery stack 10 including a plurality of stacked battery cells 11, and the conductive block 20 having a busbar 25 electrically connected to battery leads 115 of the plurality of battery cells 11.

[0033] The battery cell 11 includes a negative electrode plate 110, a positive electrode plate 111, and a separator 113 located between the negative electrode plate 110 and the positive electrode plate 111.

[0034] The negative electrode plate 110 is provided with a negative electrode lead 115, and the positive electrode plate 111 is provided with a positive electrode lead 115.

[0035] The negative electrode plate 110, the separator 113 and the positive electrode 111 are stacked sequentially in the battery cell 11, and the battery cell 11 is wrapped in a bag.

[0036] At this point, the negative lead 115 and the positive lead 115 are exposed to the outside of the bag.

[0037] The battery stack 10 is formed by stacking multiple battery cells 11, and a fixing plate 13 is arranged on each side of the width direction of the battery stack 10.

[0038] In addition, conductive blocks 20 are assembled at both ends of the battery cell 11 along its length.

[0039] The conductive block 20 is combined with the fixing plate 13 on both sides to form a through hole 23, through which each battery lead 115 of the battery cell 11 can pass and be exposed to the outside.

[0040] The conductive block 20 includes busbars 25 that are respectively connected to the battery leads 115.

[0041] Optionally, the partition wall 21 may be located between adjacent busbars 25.

[0042] The conductive block 20 is electrically connected to the battery cell 11 via the battery lead 115 and the bus bar 25.

[0043] Busbar 25 and battery lead 115 are joined by laser welding to form an electrical contact between them.

[0044] The battery stack 10 and the conductive block 20 are assembled using the apparatus 30 for assembling battery modules according to various exemplary embodiments of the present invention.

[0045] Figure 2 This is a schematic diagram showing the first side of an apparatus for assembling a battery module according to various exemplary embodiments of the present invention. Figure 3 This is a schematic diagram of the other side of an apparatus for assembling a battery module according to various exemplary embodiments of the present invention.

[0046] Reference Figure 2 and Figure 3 According to various exemplary embodiments of the present invention, the apparatus 30 for assembling a battery module includes: a clamp base 40, a bending blade 50, a clamp plate 60, and a bending link 70.

[0047] In the following text, refer to Figure 2 The reference directions describing its front-back, left-right, and vertical directions are as follows: the part facing upward is called the upper part, upper end, upper surface, and upper end; the part facing downward is called the lower part, lower end, lower surface, and lower end.

[0048] The above definition of reference direction is relative and may not be limited to, as directionality may vary depending on the reference position of the exemplary device or the components used therein.

[0049] Furthermore, in the following text, "end (one end, the other end, etc.)" may be defined as any end or as the portion including that end (one end, the other end, etc.).

[0050] The clamp base 40 can be mounted on the robotic arm used to operate the device 30.

[0051] The clamp base 40 includes a flange 41 mounted on the robotic arm, the flange 41 forming a fastening hole 42 to fasten the clamp base 40 to the robotic arm (e.g., by bolt engagement).

[0052] The clamp base 40 includes a rear base 43 integrally formed with the flange 41 and a front base 44 integrally formed with the rear base 43. The width of the front base 44 (i.e., Figure 2 The vertical direction of the middle section is smaller than the width of the rear base 43.

[0053] Mounting part 45 is formed in clamp base 40 to pass through front base 44 and rear base 43.

[0054] In addition, engagement grooves 46 are formed on both sides of the front base 44 of the clamp base 40.

[0055] The groove 46 can be formed along the two sides of the front base 44.

[0056] A slot 47 is formed on the fixture base 40, and the slot 47 passes through the rear base 43 and the front base 44.

[0057] The slot 47 extends through the rear base 43 and is formed between the clamp plate 60 and the curved blade 50.

[0058] In addition, a mounting hole 48 is formed in the clamp base 40, which passes through the rear base 43 and the flange 41.

[0059] The curved blade 50 is disposed in the fixture base 40.

[0060] The curved blade 50 is inserted into the mounting portion 45 of the clamp base 40 and is elastically supported in front of it by the first leaf spring 80 mounted on the first side of the rear base 43.

[0061] The curved blade 50 is configured to press the edge of the battery lead 115 against the busbar 25 by means of an inclined surface, which is elastically supported by the first leaf spring 80.

[0062] Furthermore, the curved blade 50 is formed in the shape of a plate and includes a front surface 51, which is formed to be inclined to form a bevel.

[0063] The curved blade 50 has a width corresponding to the length of the battery lead 115 of the battery cell 11, and can contact the battery lead 115 through the front surface 51.

[0064] Furthermore, the clamp plate 60 is disposed outside the clamp base 40 and is configured to slide along the clamp base 40 in its front-rear direction.

[0065] The clamp plate 60 includes a plate-shaped body 61 formed corresponding to the clamp base 40.

[0066] The clamp plate 60 includes a joint 63 that extends integrally from both sides of the body 61 and bends on both sides.

[0067] The clamp plate 60 is engaged with the engagement grooves 46 on the two sides of the front base 44 via the engagement portion 63.

[0068] In addition, the clamp plate 60 includes a protrusion 65 that protrudes from the rear center of the body 61 to be integrally formed therewith.

[0069] The clamp plate 60 is configured to pass through the mounting hole 48 of the rear base 43 via the protrusion 65.

[0070] At this point, the protrusion 65 can be operated by being attached to a separate robot.

[0071] In addition, the clamp plate 60 includes a support 67 that extends integrally from the two rear ends of the body 61 and bends thereon.

[0072] The clamp plate 60 is elastically supported by a second leaf spring 81 mounted on the second side of the rear base 43 via a support 67.

[0073] The bending link 70 is mounted on the front end of the clamp plate 60.

[0074] The bending link 70 is hinged to the front end of the clamp plate 60 and is configured such that when it contacts the battery lead 115, the second leaf spring 81 presses the battery lead 115 against the busbar 25 while the bending link 70 rotates until it is perpendicular to the clamp plate 60. When the bending link 70 is perpendicular to the clamp plate 60, it contacts the clamp base 40 and stops rotating.

[0075] The bending link 70 is formed parallel to the clamp plate 60 and the bending cutter 50, and includes hinge portions 71 that are bent at both ends of the bending link 70. The hinge portions 71 are hinged to the front end of the body 61 of the clamp plate 60, so that the bending link 70 can rotate.

[0076] Furthermore, the bending link 70 forms a hollow space 73 relative to the body 61 of the clamping plate 60 by hinged to the body 61 of the clamping plate 60, that is, it is located between the bending link 70 and the body 61 of the clamping plate 60.

[0077] At this time, when pressure is applied to the battery lead 115, the bending link 70 rotates to be perpendicular to the clamp plate 60 by contacting the battery lead 115. In this state, the hollow space 73 and the slot 47 of the clamp base 40 are arranged in a straight line perpendicular to the battery stack 10.

[0078] In the current state, the laser beam B can be irradiated through the slot 47 toward the hollow space 73 to weld the battery lead 115 to the bus bar 25 through the hollow space 73.

[0079] The bending link 70 includes a return spring 75 mounted on the hinge portion 71.

[0080] The return spring 75 can apply pressure to the battery lead 115 bent by the bending knife 50 to better contact the busbar 25, and can apply a restoring force to the bending link 70 when the welding process is completed.

[0081] An exemplary method for assembling a battery module, comprising a battery stack 10 and a conductive block 20, the battery stack 10 including a plurality of stacked battery cells 11, the conductive block 20 having a busbar 25 electrically connected to battery leads 115 of the plurality of battery cells 11.

[0082] Figure 4 A view is shown of a method for assembling a battery module according to various exemplary embodiments of the present invention.

[0083] Reference Figure 4 First, the clamp base 40 moves toward the battery unit 11.

[0084] After moving the clamp base 40 a predetermined distance toward the battery unit 11, the battery lead 115 is first bent relative to the busbar 25 by the bending cutter 50.

[0085] At this time, the front surface 51 of the curved blade 50, which forms an inclined surface, corresponds to the end of the battery lead 115 and is located at the edge of the busbar 25.

[0086] Furthermore, the front surface 51 of the bending blade 50 presses the end of the battery lead 115 to bend it based on an inclined plane, for example, towards... Figure 4 The right side of the bend is bent. In this case, the front surface 51 of the bending knife 50 presses the end of the battery lead 115 to bend it according to the bevel.

[0087] Subsequently, the clamp base 40 moves further toward the battery cell 11, so that the battery lead 115 bends twice toward the busbar 25 via the bending link 70, forming a close contact with the busbar 25.

[0088] At this time, as the clamp base 40 moves further toward the battery unit 11, the curved blade 50 retracts toward the clamp base 40, while the first leaf spring 80 supporting the curved blade 50 toward the battery lead 115 presses the battery lead 115.

[0089] The clamp base 40 moves toward the battery cell 11 until the bending link 70 is perpendicular to the body 61 of the clamp plate 60, that is, until the bending link 70 is parallel to the busbar 25. During this process, under the elastic force of the second leaf spring 81 and the return spring 75, the battery lead 115 is further pressed against the busbar 25. When the bending link 70 is perpendicular to the clamp plate 60, the bending link 70 contacts the clamp base 40 and stops rotating.

[0090] In its current state, the bending link 70 can pressurize the entire front surface of the battery lead 115, thereby creating a completely tight contact between the battery lead 115 and the busbar 25.

[0091] Finally, the laser beam B is irradiated through the hollow space 73 between the bent connecting rod 70 and the clamp plate 60, thereby welding the battery lead 115 to the busbar 25.

[0092] That is, when the bent connecting rod 70 is perpendicular to the clamp plate 60 and contacts the clamp base 40, the laser beam B is irradiated through the slot 47 of the clamp base 40, which is arranged in a straight line with the hollow space 73.

[0093] Subsequently, the clamp base 40 retracts, and the bending link 70 returns to its initial state via the return spring 75 mounted on the hinge portion 71 of the bending link 70 and the body 61 of the clamp plate 60.

[0094] Therefore, in the apparatus and method for assembling battery modules according to various exemplary embodiments of the present invention, the battery lead 115 of the battery cell 11 bends toward the busbar 25 and is forced into close contact with the busbar 25, thereby reducing the cycle time of the welding process.

[0095] The apparatus and method for assembling battery modules according to various exemplary embodiments of the present invention can simplify the entire process, reduce investment costs and increase productivity.

[0096] For ease of description and precise definition in the appended claims, the terms “upper,” “lower,” “internal,” “external,” “up,” “lower,” “upward,” “downward,” “front,” “rear,” “rearward,” “internal,” “external,” “inward,” “outward,” “internal,” “external,” “inner side,” “outer side,” “forward,” and “backward,” etc., are used to describe features in the positions shown in the accompanying drawings with reference to the features of the exemplary embodiments. It will be further understood that the term “connection” or its derivatives refer to both direct and indirect connections.

[0097] For purposes of illustration and description, the foregoing description of specific exemplary embodiments of the invention has been provided. This description is not intended to be exhaustive or to limit the invention to the exact forms disclosed, and various modifications and variations will be apparent from the foregoing teachings. Exemplary embodiments were chosen and described to explain the specific principles of the invention and its practical application, thereby enabling others skilled in the art to implement and utilize various exemplary embodiments of the invention and their various alternatives and variations. The scope of the invention is intended to be defined by the appended claims and their equivalents.

Claims

1. An apparatus for assembling battery modules, the apparatus being configured to assemble a battery stack and a conductive block, the battery stack comprising a plurality of stacked battery cells, the conductive block having a busbar electrically connected to battery leads of the plurality of battery cells, the apparatus comprising: The fixture base includes a rear base and a front base integrally formed therefrom; A curved blade is slidably disposed in the clamp base, the curved blade having a front surface for selectively contacting at least one battery lead, and being elastically supported by a first leaf spring formed on a first side of the rear base; A clamping plate is disposed outside the clamping base and configured to slide along the clamping base in a predetermined direction; as well as A bending link, pivotally engaged with the front end of the clamping plate, is configured to rotate a predetermined angle relative to the clamping plate when pressure is applied to the at least one battery lead. The front surface of the curved blade is formed to be inclined to create a bevel. The bending blade is configured such that, elastically supported by the first leaf spring, the beveled surface presses the edge of at least one battery lead against the busbar, causing the at least one battery lead to bend according to the beveled surface. The bent connecting rod is pivotally engaged with the front end of the clamping plate and forms a hollow space relative to the front end of the clamping plate. When pressure is applied to the at least one battery lead, the bending link is configured to rotate perpendicular to the clamp plate by contacting the at least one battery lead, causing the at least one battery lead to bend twice toward the busbar to form a tight contact with the busbar, and the at least one battery lead is welded to the busbar using a laser beam passing through the hollow space.

2. The apparatus of claim 1, wherein, The clamp plate is engaged with the first and second side surfaces of the front base via a connecting portion, the connecting portion extending integrally from the first and second sides of the plate-shaped body corresponding to the clamp base and bending on the first and second sides.

3. The apparatus of claim 2, wherein, The clamp plate is configured to pass through a mounting hole formed on the rear base via a protrusion, the protrusion being integrally formed with and protruding from the rear central portion of the body.

4. The apparatus of claim 2, wherein, The clamp plate is elastically supported by a second leaf spring formed on the second side of the rear base via a support portion, which extends integrally from the two rear ends of the body and bends at the two rear ends.

5. The apparatus as described in claim 1, in, A slot is formed on the rear base between the clamping plate and the curved blade, and When the bending connecting rod is perpendicular to the clamp plate, the hollow space and the slot of the clamp base are perpendicular to the battery stack in a straight line.

6. The apparatus of claim 2, wherein, The bending link includes a spring mounted on the hinge portion between the bending link and the clamping plate.

7. A method for assembling a battery module, comprising assembling a battery stack and a conductive block using an apparatus for assembling a battery module according to any one of claims 1 to 6, the battery stack comprising a plurality of stacked battery cells, the conductive block having a busbar electrically connected to battery leads of the plurality of battery cells, the method comprising the following steps: By moving the clamp base toward the battery cell, at least one battery lead is bent relative to the busbar using a bending cutter. By moving the clamp base further toward the battery cell, the bending link is used to bend the at least one battery lead toward the busbar. as well as The at least one battery lead is welded to the busbar by irradiating a laser beam through the hollow space between the curved connecting rod and the clamp plate.

8. The method of claim 7, wherein, In the step of bending at least one battery lead relative to the busbar The front surface of the beveled surface of the curved blade is located at the end of the at least one battery lead; and The front surface of the bending blade is used to press the end of the at least one battery lead to bend it along the inclined plane.

9. The method of claim 7, wherein, In the step of bending the at least one battery lead toward the busbar, while the at least one battery lead is pressurized by a first leaf spring supporting the bending blade toward the battery lead, the bending blade retracts toward the clamp base.

10. The method of claim 7, wherein, In the step of bending the at least one battery lead toward the busbar, the clamp base is moved toward the at least one battery lead until the bending link is perpendicular to the clamp plate and contacts the clamp base.

11. The method of claim 7, wherein, In the step of bending the at least one battery lead toward the busbar, the bending link presses the at least one battery lead toward the busbar by a second leaf spring supporting the clamp plate.

12. The method of claim 7, wherein, In the step of welding at least one battery lead to the busbar, when the bent connecting rod is perpendicular to the clamp plate and contacts the clamp base, a laser beam is irradiated through a slot in the clamp base that is arranged in a straight line with the hollow space.

13. The method of claim 7, further comprising the following steps: After the at least one battery lead is soldered to the busbar, the bent link is returned to its initial state by a spring mounted on the hinge between the bent link and the clamp plate.

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