Battery Module Bus Bar Bonding for Stable Welded Connections
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Solution Overview
Problem
The challenge in battery modules is ensuring stable electrical connections between battery cells and bus bars, as improper welding can lead to safety and performance issues due to separation under shock, necessitating improved bonding geometries to reduce process dispersion.
Innovation Solution
A battery module design featuring specific bonding portions with varying sizes and positions on battery cells to enhance the welding process, including a larger second bonding portion positioned closer to adjacent cells, which can be welded using methods like electron beam, laser, or ultrasonic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform bonding portions are used on battery cells, then the welding process is simple, but process dispersion occurs leading to incomplete welding and connection instability
Solution Approach 1:
The bonding portions are designed with non-uniform sizes, where a first bonding portion and a second bonding portion have different dimensions. The second bonding portion has a larger area than the first bonding portion, creating local quality variations that compensate for welding process dispersion and ensure complete welding across all bonding regions.
Solution Approach 2:
The bonding portions are configured asymmetrically in terms of size and position. The second bonding portion is positioned closer to another battery cell and has a larger area compared to the first bonding portion. This asymmetric design ensures that even with process dispersion, all bonding portions are properly welded, improving connection reliability.
2Strength
If bonding portions are positioned uniformly, then the manufacturing process is simple, but connection stability under shock is insufficient
Solution Approach 1:
The bonding portions are configured asymmetrically in terms of size and position. The second bonding portion is positioned closer to another battery cell and has a larger area compared to the first bonding portion. This asymmetric design ensures that even with process dispersion, all bonding portions are properly welded, improving connection reliability.
Solution Approach 2:
The bonding portions are designed with non-uniform sizes, where a first bonding portion and a second bonding portion have different dimensions. The second bonding portion has a larger area than the first bonding portion, creating local quality variations that compensate for welding process dispersion and ensure complete welding across all bonding regions.
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 stabilizes the connection between battery cells and bus bars, reducing resistance and heat generation, thereby enhancing safety and performance by minimizing incomplete welding and maintaining efficient electrical conductivity.
Implementation Method 1
The bonding portion may bond the battery cell and the bus bar by welding
Implementation Method 2
The welding may include at least one of electron beam welding, laser welding, ultrasonic welding, and friction welding
Implementation Method 3
The welding may include at least one of electron beam welding, laser welding, ultrasonic welding, and friction welding
Implementation Method 4
The welding may include at least one of electron beam welding, laser welding, ultrasonic welding, and friction welding
Implementation Method 5
The welding may include at least one of electron beam welding, laser welding, ultrasonic welding, and friction welding
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A battery module includes a plurality of battery cells, a bus bar configured to electrically connect at least two of battery cells, and bonding portions configured to bond the battery cells to the bus bar. Each of the bonding portions includes a first bonding portion formed on a first region of one of the battery cells, and a second bonding portion formed on a second region of the battery cell, with the second bonding portion being larger than the first bonding portion.