Battery Module Bus Bar Structure to Block Laser Beam Penetration
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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 includes guide chamfers and a beam penetration prevention structure that extends downward and is inclined, preventing the laser beam from penetrating towards the battery cells by guiding the welding process and maintaining close contact between electrode leads and bus bar surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is performed to connect electrode leads and bus bar, then electrical connection is achieved, but laser beam may penetrate through gap space and damage battery cell body
Solution Approach 1:
The patent introduces a beam penetration prevention guider as an intermediary component between the laser beam and the battery cell body. This guider structure intercepts and redirects the laser beam, preventing it from penetrating through the gap space to damage the battery cell body, while allowing the laser welding process to proceed effectively for electrical connection.
Solution Approach 2:
The patent adds a new spatial dimension by extending the bus bar structure downward to form a guider that protrudes into the gap space. This three-dimensional extension creates a physical barrier in the vertical dimension that blocks the laser beam's path, solving the penetration issue without affecting the horizontal welding connection.
2Adaptability or versatility
If gap space is generated due to assembling tolerance, then assembly flexibility is improved, but laser beam penetration and battery cell damage occur
Solution Approach 1:
The patent applies preliminary anti-action by pre-configuring the beam penetration prevention guider structure on the bus bar before assembly. This guider proactively counteracts the potential harmful effect of laser beam penetration that would occur due to assembly gaps, neutralizing the risk before the welding process begins while maintaining assembly flexibility.
3Manufacturing precision
If electrode lead is bent to achieve close contact with bus bar, then welding quality is improved, but additional manufacturing process is required
Solution Approach 1:
Instead of bending the electrode lead to achieve close contact, the patent inverts the approach by extending the bus bar structure downward to meet the electrode lead. This reversal eliminates the need for bending the lead, achieving the same welding contact precision 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 bus bar having a beam penetration prevention guider configured to prevent a laser beam from penetrating toward the plurality of battery cells during the laser welding
Implementation Method 2
The electrical connection generally connects the electrode leads of the battery cells and the bus bar to each other by laser welding
Data Source
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AI summary
A battery module 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 cells by laser welding, the bus bar having a beam penetration prevention guider configured to prevent a laser beam from penetrating toward the plurality of battery cells during the laser welding.