Battery Module Bus Bar Welding Without Electrode Lead Bending
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Solution Overview
Problem
Conventional methods for producing battery modules require bending electrode leads to couple them with bus bars, leading to poor adhesion, weldability issues, and manual labor, which decreases automation efficiency.
Innovation Solution
A method involving a welding jig to press and weld electrode leads directly onto bus bars without bending, using inclined or horizontal portions on the bus bars for secure contact and coupling, eliminating manual bending and overlapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrode leads are bent to contact bus bar surface, then electrode leads can be coupled to bus bar, but adhesion is poor and manual work is required
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 contact the electrode lead. The bus bar is formed with an inclined portion that actively engages with the electrode lead, eliminating the need for manual bending operations and enabling automated coupling processes.
Solution Approach 2:
The bus bar is pre-formed with an inclined portion during manufacturing, which prepares the coupling interface in advance. This preliminary action eliminates the need for subsequent bending operations and ensures proper alignment and contact between the bus bar and electrode lead during assembly.
2Ease of manufacture
If electrode leads are bent to contact bus bar, then coupling is achieved, but elastic recovery force prevents close adhesion
Solution Approach 1:
The invention reverses the active element: instead of the electrode lead actively bending to contact the bus bar, the bus bar with its inclined portion actively engages and presses against the electrode lead. This inversion eliminates elastic recovery issues because the electrode lead remains in its natural straight state while being contacted by the bus bar.
3Productivity
If multiple electrode leads are overlapped at one bus bar point, then welding is possible, but weldability deteriorates
Solution Approach 1:
The bus bar is segmented into multiple inclined portions at different positions along its length. Each inclined portion corresponds to a different electrode lead, distributing the welding locations along the bus bar rather than concentrating multiple leads at a single point. This segmentation maintains welding efficiency while improving weldability by avoiding overlapping.
4Ease of manufacture
If manual bending of electrode leads is performed, then coupling is achieved, but production line automation is reduced
Solution Approach 1:
The bus bar is pre-formed with inclined portions during manufacturing, which prepares the coupling interface in advance. This preliminary action eliminates the need for subsequent manual bending operations on the production line, enabling fully automated coupling processes while maintaining coupling capability.
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 ensures close adhesion and improved weldability between electrode leads and bus bars, enhancing automation by eliminating manual bending and preventing elastic recovery issues.
Implementation Method 1
by a welding jig, pressing the electrode leads so that the electrode leads come into contact with the bus bars, respectively
Implementation Method 2
welding the electrode leads and the bus bars through an opening formed in the welding jig
Data Source
AI summary
A method for producing a battery module is provided. The method for producing a battery module includes: stacking a plurality of battery cells; disposing a plurality of bus bars adjacent to electrode leads respectively provided at the plurality of battery cells; by a welding jig, pressing the electrode leads so that the electrode leads come into contact with the bus bars, respectively; and welding the electrode leads and the bus bars through an opening formed in the welding jig.