Battery Module Bus Bar Guider for Laser Weld Beam Blocking
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Solution Overview
Problem
During the laser welding of electrode leads and bus bars in battery modules, gaps due to assembling tolerance can cause laser beams to penetrate through, potentially damaging battery cells.
Innovation Solution
Incorporating a beam penetration prevention guider on the bus bar, which is inclined and extends from guide chamfers, preventing the laser beam from penetrating towards the battery cells by maintaining close contact between electrode leads and bus bar sides without bending, and being integrally formed with the bus bar body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to connect electrode leads and bus bar, then manufacturing efficiency is improved, but gaps due to assembling tolerance cause laser beam penetration and damage to battery cells
Solution Approach 1:
The patent introduces a guider structure as an intermediary element between the laser beam and the battery cell. This guider, integrated with the bus bar, acts as a protective mediator that intercepts and redirects the laser beam, preventing it from penetrating through gaps to damage the battery cell body while allowing the welding process to proceed efficiently.
Solution Approach 2:
The guider structure is designed and positioned in advance during bus bar fabrication, before the welding operation occurs. This preliminary configuration ensures that the laser beam is already directed along a safe path, preventing potential damage before it can occur during the welding process.
2Reliability
If electrode leads are allowed to bend for close contact with bus bar, then welding reliability is improved, but additional bending processes increase manufacturing complexity
Solution Approach 1:
The electrode lead is designed with inherent flexibility that allows it to self-adjust and make close contact with the bus bar surface through its own elastic deformation during the welding process. This self-service mechanism eliminates the need for external bending tools or additional forming processes, maintaining welding reliability while simplifying the manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents laser beam penetration through gaps generated by assembling tolerance, thereby protecting battery cells from damage and improving manufacturing efficiency by eliminating the need for additional bending processes.
Implementation Method 1
The electrical connection generally connects the electrode leads of the battery cells and the bus bar to each other by laser welding
Data Source
AI summary
Discussed is a battery module that includes a plurality of battery cells having electrode leads protruding in at least one direction; and at least one bus bar disposed at one side of the plurality of battery cells and connected to the electrode leads of the plurality of battery, the bus bar having a beam penetration prevention guider configured to prevent a laser beam from penetrating toward the plurality of battery cells during a laser welding.