Battery Module Busbar Layout for Accessible Lead Welding
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Solution Overview
Problem
Conventional battery module welding processes are costly due to the use of busbars and plating, and the quality of welding is difficult to ensure, leading to potential defects that require discarding the entire cell stack if issues arise.
Innovation Solution
A battery module design where electrode leads are welded to busbars in the same direction as the stacking direction, with busbar connection parts bent perpendicular to the busbar plate, allowing for improved welding quality and enabling individual cell replacement if defects occur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent onto busbar for welding after cell stacking, then welding connection is achieved, but welding quality cannot be guaranteed and defect detection is difficult
Solution Approach 1:
The busbar is prepared in advance with a bent connection part that protrudes perpendicular to the busbar plate before cell stacking. This preliminary preparation allows the welding surface to be exposed and accessible for quality verification, eliminating the difficulty of detecting welding contact after cell assembly.
Solution Approach 2:
The busbar connection part is bent to protrude in a direction perpendicular to the busbar plate, changing the spatial dimension of the welding surface from a hidden rear-face position to an exposed vertical position. This dimensional change enables easy visual and physical inspection of welding quality.
2Productivity
If welding is performed after stacking battery cells, then electrical connection is achieved, but the entire cell stack must be discarded if welding defects occur
Solution Approach 1:
The busbar with its bent connection part is prepared before cell stacking, allowing welding quality to be verified in advance. This preliminary verification prevents defective welds from compromising the entire cell stack, enabling individual cell replacement rather than total stack disposal.
Solution Approach 2:
The busbar is segmented into a busbar plate and a bent connection part, with the connection part serving as an accessible welding interface. This segmentation allows quality control at the busbar level before final assembly, protecting the valuable cell stack from welding defects.
3Reliability
If busbar and plating materials are used for welding, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The busbar's own structure is utilized to create the bent connection part that serves as the welding interface. This self-service approach eliminates the need for separate plating materials and additional connection components, reducing manufacturing costs while maintaining reliable electrical connection.
Solution Approach 2:
The busbar serves multiple functions: it provides electrical connection, structural support, and the bent connection part acts as both a mechanical anchor and a welding surface. This multi-functionality eliminates the need for additional specialized materials, reducing overall manufacturing cost.
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 approach simplifies the production process, enhances welding quality, and allows for the replacement of defective cells without discarding the entire stack, reducing costs and improving efficiency.
Implementation Method 1
a busbar connection part formed by being bent at one end of the busbar plate, and the busbar connection part is bent in a direction perpendicular to a surface of the busbar plate
Implementation Method 2
welded to the electrode lead
Data Source
AI summary
A battery module including a battery cell having an electrode lead protruding from an end part thereof, a cell tray on which a plurality of battery cells are mounted, and a busbar mounted on one end part of the cell tray positioned in a direction parallel to a protruding direction of the electrode lead and welded to the electrode lead. The busbar comprises a busbar plate, which is a portion welded to the electrode lead, and a busbar connection part that is formed by bending one end of the busbar plate in a direction perpendicular to a surface of the busbar plate.