Battery Module Bus Bar Structure to Block Laser Weld Penetration
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Solution Overview
Problem
During the assembly of battery modules and packs, gaps between electrode leads and bus bars can cause laser beams to penetrate and damage battery cells during laser welding, due to assembling tolerance issues.
Innovation Solution
The integration of a beam penetration prevention guider on the bus bar, which is inclined and extends from guide chamfers, prevents laser beams from penetrating through gaps by guiding the welding process and maintaining close contact between electrode leads and bus bar surfaces, thus preventing damage to battery cells.
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 physically blocks the laser beam path, preventing it from penetrating through the gap space to damage the battery cell body, while allowing the welding process to proceed normally.
Solution Approach 2:
The beam penetration prevention guider is designed to preemptively block the harmful laser beam before it can penetrate and damage the battery cell. By placing this protective structure in advance, the patent prevents the harmful effect from occurring rather than addressing it after damage happens.
2Ease of manufacture
If assembling tolerance is considered, then manufacturing feasibility is improved, but gap space is generated between electrode lead and bus bar
Solution Approach 1:
The patent divides the bus bar structure into multiple segments: the main bus bar body and the attached beam penetration prevention guiders. This segmentation allows the bus bar to accommodate positioning gaps while the guider segments extend to block laser penetration paths, thus managing both tolerance and precision requirements.
Solution Approach 2:
The beam penetration prevention guider extends in a direction perpendicular to the main bonding surface, adding a new dimensional element to the structure. This vertical extension allows the guider to reach across the gap space created by assembly tolerance and block the laser beam path without compromising the horizontal positioning tolerance.
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
This solution effectively prevents laser beam penetration through gaps generated by assembling tolerance, ensuring the integrity and safety of battery cells during the welding process, thereby enhancing manufacturing efficiency and reducing the risk of cell damage or explosion.
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 including battery cells having electrode leads protruding in at least one direction, and at least one bus bar disposed at one side of the battery cells, each of the at least one bus bar includes a bus bar body having a top planar surface parallel to a stacked direction of the battery cells, a pair of first surfaces connected to opposite sides of the top planar surface, respectively, and extending away from the top planar surface, the pair of first surfaces having a first slope relative to the top planar surface. The pair of first surfaces are inclined, and a pair of second surfaces directly connected to the pair of first surfaces, respectively, and extending away from the pair of first surfaces, the pair of second surfaces having a second slope relative to the top planar surface that is different from the first slope.