Battery Module Bus Bar Support for Reliable Lead Welding
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Solution Overview
Problem
Conventional battery modules face reliability issues in the welding portion between electrode leads and bus bars due to unstable contact and mechanical rigidity limitations, which affect manufacturing costs and efficiency.
Innovation Solution
A battery module design incorporating a bus bar frame with an insertion space and a jig support to stabilize the bus bar and welding jig, ensuring consistent contact between the electrode lead and bus bar, and reducing the thickness of the bus bar while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is supported only by the bus bar frame without additional jig support, then the structure is simpler, but the welding reliability deteriorates due to unstable contact between electrode lead and bus bar
Solution Approach 1:
A jig support component is introduced as an intermediary element between the bus bar frame and the welding jig. This mediator provides stable support for the welding jig during the welding process, ensuring consistent contact between the electrode lead and bus bar, thereby improving welding reliability without requiring the bus bar itself to bear the full pressing force
Solution Approach 2:
The bus bar frame structure is segmented into multiple functional components: the bus bar frame body, the jig support component, and the bus bar. This segmentation allows each component to perform its specific function - the frame provides structural support, the jig support ensures welding jig stability, and the bus bar conducts electricity - resolving the contradiction between structural simplicity and welding reliability
2Strength
If the bus bar thickness is increased to support the welding jig pressing force, then the mechanical rigidity is improved, but the manufacturing cost and weight increase
Solution Approach 1:
The jig support component acts as a force distribution intermediary, transferring the welding jig pressing force to the bus bar frame rather than concentrating it on the bus bar. This allows the bus bar to maintain thinner dimensions with reduced weight while still providing sufficient mechanical rigidity for welding operations
Solution Approach 2:
Instead of increasing bus bar thickness (one-dimensional solution), the design adds a jig support component in the vertical dimension between the welding jig and bus bar. This dimensional approach distributes the mechanical load through the frame structure, allowing the bus bar to remain thin and lightweight while maintaining adequate strength
3Strength
If the bus bar thickness is increased to maintain mechanical rigidity, then the structural stability is improved, but the manufacturing cost increases
Solution Approach 1:
The jig support component serves as a mediator that handles the mechanical loading requirements, allowing the bus bar to be manufactured with thinner, less expensive materials while maintaining structural stability during welding operations
Solution Approach 2:
The design changes the structural configuration parameters by introducing a separate jig support component rather than relying solely on bus bar thickness. This parameter change enables the use of thinner, more cost-effective bus bar materials while maintaining the necessary mechanical rigidity through the overall frame-jig support-bus bar system
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 enhances welding reliability and reduces manufacturing costs by stabilizing the bus bar and welding jig, allowing for improved weldability and potentially smaller, lighter battery modules.
Implementation Method 1
the electrode lead is pressed toward the bus bar by using a welding jig to be in close contact with the bus bar
Implementation Method 2
welding is performed by emitting a laser to the electrode lead
Implementation Method 3
welding is performed by emitting a laser to the electrode lead
Data Source
AI summary
Discussed is a battery module in which welding reliability between an electrode lead and a bus bar may be improved and manufacturing costs reduced. A battery module may include a plurality of battery cells each including an electrode lead, a bus bar including a lead welding portion adhered to the electrode lead of each of the plurality of battery cells, and a bus bar frame including an insertion space into which at least a portion of the bus bar is inserted, and a jig support configured to support a welding jig that is configured to press the electrode lead, in a direction opposite to a pressing direction of the welding jig.