Battery Module Housing Anti-Slip Guide for Busbar Welding Stability
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Solution Overview
Problem
Conventional battery module assembly processes face challenges with asymmetrical slipping of busbars during welding, leading to poor welding quality, unstable dispersion, and potential damage to battery cells due to the lack of support for the upper part of the busbar assembly.
Innovation Solution
The introduction of a battery module housing with an anti-slip guide structure that includes a sensing busbar assembly with jig holes at both ends, allowing for even support and alignment of the busbar assembly, thus eliminating the need for a separate counter bar and preventing slipping during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a counter bar is used to support the lower part of the battery cell during welding, then the pressing force can be maintained and welding space can be secured, but the busbar slips upward asymmetrically causing poor welding quality and jig deformation
Solution Approach 1:
The support function is segmented from a single counter bar to multiple support points: the counter bar supports the lower part while the housing supports the upper part, distributing the support function across multiple locations to prevent asymmetric slipping
Solution Approach 2:
The housing acts as an intermediary support structure between the busbar and the upper part of the assembly, preventing the busbar from slipping upward by providing a stable reference point during the welding process
2Ease of manufacture
If the counter bar enters only from the lower end, then the assembly process is simplified, but the upper part lacks support causing asymmetry and potential damage to battery cells
Solution Approach 1:
The support function is merged from a single counter bar into a combined system where the counter bar supports the lower part and the housing supports the upper part, achieving both simplified assembly and improved reliability
3Productivity
If the jig is used repeatedly without proper support, then productivity is maintained, but continuous force causes deformation and damage to the product and jig
Solution Approach 1:
The housing provides beforehand cushioning support for the upper part of the busbar assembly, preventing deformation and damage before they can occur during repeated welding operations, thereby extending the durability of both the product and jig
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 solution enhances the quality and stability of the welding process between cell leads and busbars, reduces deformation of the jig and battery cells, and extends the jig replacement cycle, thereby improving process capability and reducing costs.
Implementation Method 1
cell leads each protruding from either end of a cell and a busbar electrically connecting the cell leads to each other may be coupled to each other by laser welding
Data Source
AI summary
Provided is a battery module housing with an anti-slip guide structure to prevent its product or jig from being deformed, and more particularly, to the battery module housing including: an upper housing, a lower housing, a front housing, and a rear housing, respectively disposed on the upper, lower, front, and rear surfaces of the plurality of battery cells along their peripheries, the battery cells being in surface-contact with each other and arranged in one direction; a pair of side housings each disposed to be adjacent to and surrounding a cell lead protruding from either end of the battery cell in a length direction; and a sensing busbar assembly disposed between the side housing and the cell lead, and connecting the plurality of cell leads to each other, wherein the sensing busbar assembly includes a jig hole into which a jig for supporting the sensing busbar assembly is configured to be inserted.