Battery Module Bus Bar Holder for Clearance-Free Tab Welding
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Solution Overview
Problem
In battery modules, poor welding can occur due to clearances between stacked electrode tabs and between the tabs and the bus bar, leading to inadequate connections.
Innovation Solution
A battery module design featuring bus bars held by an electrical insulating bus bar holder with slit openings, where the tabs are drawn through these openings and connected to plate-shaped tab connection portions on the bus bar holder, and a sandwiching tool is used to ensure proper alignment and welding of the tabs and bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple electrode tabs are stacked and welded to a bus bar, then the electrical connection capability is improved, but clearances between stacked tabs and between tabs and bus bar cause poor welding
Solution Approach 1:
The bus bar holding member acts as an intermediary component that provides a common mounting base for multiple bus bars. By holding the bus bars at fixed intervals with precise positioning, it ensures consistent alignment between the bus bars and electrode tabs during welding, eliminating clearance issues caused by manual stacking.
Solution Approach 2:
The bus bars are pre-positioned and fixed to the bus bar holding member before the welding process. This preliminary positioning ensures that the bus bars are already aligned at the correct locations and orientations, so when electrode tabs are stacked and welded, no clearances or misalignments occur.
2Volume of moving object
If bus bars are held close together to save space, then the device compactness is improved, but clearances between bus bars and tabs increase causing poor welding
Solution Approach 1:
The bus bar holding member segments the positioning function for multiple bus bars, providing individual positioning features for each bus bar while maintaining fixed intervals. This segmentation allows precise control of each bus bar's position relative to the others, ensuring proper alignment even when bus bars are closely spaced.
Solution Approach 2:
The bus bar holding member serves as a mediator that manages the spatial relationship between closely spaced bus bars and the electrode tabs. It provides the necessary positioning and support to maintain welding quality despite the reduced spacing between components.
3Ease of manufacture
If bus bars are held without precise positioning to simplify manufacturing, then the manufacturing complexity is reduced, but clearances form between stacked tabs and bus bars
Solution Approach 1:
The bus bar holding member performs multiple functions simultaneously: it holds multiple bus bars, positions them at fixed intervals, provides alignment references for welding, and supports the overall structure. This multi-functionality achieves precise alignment without significantly increasing manufacturing complexity.
Solution Approach 2:
The bus bar holding member is prepared in advance with pre-formed positioning features and mounting structures. This preliminary preparation allows bus bars to be quickly installed in the correct positions during assembly, maintaining high 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
This design ensures proper connection and welding of the tabs and bus bars, preventing clearances and improving welding quality.
Implementation Method 1
sandwiching the tab connection portion and the multiple tabs with a sandwiching tool
Implementation Method 2
welding the tab connection portion and the multiple tabs to each other with the tab connection portion and the multiple tabs sandwiched by the sandwiching tool
Data Source
AI summary
Provided is a battery module configured so that connection among tabs and a bus bar stacked on each other is properly made. The battery module includes: multiple battery cells 10 each of which has tabs 101, 102; bus bars 152, 153 electrically connecting the battery cells to each other; and an electrical insulating bus bar holder 150 holding the bus bars 152, 153 such that the bus bars 152, 153 are arranged apart from each other in parallel. The bus bar holder 150 has, in regions adjacent to the bus bars 152, 153, slit openings 156b to 156e through which the tabs 101, 102 are drawn. The bus bars 152, 153 include plate-shaped tab connection portions standing on an outer peripheral surface of the bus bar holder 150 and joined to the tabs 101, 102.