Battery Module Bus Bar and Sensing Assembly Without Lead Bending
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Solution Overview
Problem
The existing battery module assembly process is inefficient due to the need for manual bending and welding of electrode leads to bus bars, leading to issues with maintaining contact and weldability, and requires numerous wires for voltage detection, increasing the risk of defects and complexity.
Innovation Solution
A battery module design featuring a bus bar assembly with recessed structures and a sensing assembly that includes a circuit board and sensing frame, allowing for easy electrical connection of electrode leads without bending, improved contact maintenance, and reduced wire usage, with a sensing terminal for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent to contact bus bar surface, then electrical connection is achieved, but manual operations are required and elastic recovery causes poor adhesion
Solution Approach 1:
Instead of bending the electrode lead to contact the bus bar surface, the invention inverts the approach by making the bus bar conform to the electrode lead's natural flat surface. The bus bar is bent to match the curvature of the electrode lead, eliminating the need to bend the lead itself and avoiding elastic recovery issues.
Solution Approach 2:
The invention applies preliminary action by pre-bending the bus bar to the correct curvature before assembly. The bus bar is formed in advance with a bent shape that matches the electrode lead's surface, so that when assembled, the contact is achieved without requiring manual bending operations during assembly.
2Reliability
If electrode leads are bent for welding, then electrical connection is achieved, but weldability decreases due to difficulty in maintaining overlap state
Solution Approach 1:
The invention inverts the conventional approach by not bending the electrode lead for welding. Instead, the bus bar is bent to contact the flat surface of the electrode lead, allowing the welding process to be performed on stable, non-bent components that maintain proper overlap and alignment throughout welding.
3Reliability
If numerous wires are used for voltage detection, then sensing capability is achieved, but assembly complexity and defect risk increase
Solution Approach 1:
The invention merges the sensing function with the existing bus bar structure. The bus bar serves dual purposes: providing electrical connection for power transmission and incorporating sensing capabilities through integrated sensing electrodes or traces on the same bus bar structure, eliminating the need for separate sensing wires.
Solution Approach 2:
The bus bar is designed with multi-functionality, serving both as a power transmission conductor and as a sensing element. By integrating voltage detection capability into the bus bar itself, the system reduces the number of components while maintaining both power delivery and sensing functions.
Data Source
AI summary
A battery module includes: a cell stack defined by a plurality of battery cells each including a positive electrode lead, a negative electrode lead, and at least one of a sensing negative electrode lead and a sensing positive electrode lead; a bus bar assembly including a plurality of connection bus bars electrically connected to one of the positive and negative electrode leads, a plurality of sensing bus bars electrically connected to the sensing negative electrode lead or the sensing positive electrode lead, and a plurality of bus bar frames including a connection accommodating portion for receiving one of connection bus bars and a sensing accommodating portion for receiving one of sensing bus bars; and a sensing assembly including a sensing frame that receives a circuit board electrically connected to the plurality of connection bus bars and the plurality of sensing bus bars.