Battery Module Pressing Jig for Bus Bar Welding Without Lead Bending
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Solution Overview
Problem
Conventional battery module manufacturing processes require bending of electrode leads, which complicates the process and reduces bonding strength due to shorter electrode leads, increasing the risk of product failure, especially with pouch-type cells.
Innovation Solution
A pressing jig with a first and second frame, connected by a hinge and a restoring member, allows for adjustable pressing units to securely grip and align bus bars, eliminating the need for electrode lead bending by ensuring close contact and adherence during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode lead is bent to adhere to the bus bar, then the electrode lead can be positioned for welding, but the process becomes complicated and bonding strength decreases
Solution Approach 1:
The invention extracts and eliminates the bending process from the manufacturing sequence. By designing the pressing jig to directly press the electrode lead against the bus bar in its original straight state, the bending step is removed entirely, simplifying the process while maintaining effective bonding.
Solution Approach 2:
Instead of bending the electrode lead to achieve contact with the bus bar, the invention inverts the approach by pressing the electrode lead and bus bar together in their natural straight configuration, achieving the same bonding objective through a reversed methodological approach.
2Length of moving object
If the electrode lead is shortened for pouch-type cells, then the cell thickness is reduced, but the bonding area decreases and bonding strength is lowered
Solution Approach 1:
The pressing jig applies pressure to the electrode lead and bus bar assembly before welding occurs. This preliminary pressing action ensures maximum contact area and intimate adhesion between the surfaces, compensating for the shorter electrode lead length and maintaining strong bonding despite reduced material length.
Solution Approach 2:
The pressing jig provides a cushioning effect by maintaining continuous pressure on the bonding interface during the welding process. This beforehand cushioning ensures that even with shorter electrode leads, the bonding area achieves sufficient contact and adhesion strength to prevent failure.
3Manufacturing precision
If the electrode lead is pressed toward the bus bar using a conventional jig, then close contact is achieved for welding, but the process requires additional bending steps
Solution Approach 1:
The pressing jig combines the positioning and pressing functions into a single integrated operation. By designing the jig to hold both the electrode lead and bus bar in their natural straight positions while applying pressing force, it merges what were previously separate bending and pressing steps into one unified action, achieving precise contact without additional process complexity.
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
Simplifies the battery module manufacturing process by eliminating the electrode lead bending step, enhancing bonding strength and reducing the risk of disconnection between electrode leads and bus bars, thereby minimizing product failures.
Implementation Method 1
the first frame and the second frame are coupled by a hinge so that a distance between first pressing unit and the second pressing unit is increased when a distance between the first distance adjusting unit and the second distance adjusting unit is decreased
Implementation Method 2
a restoring member connected between the first distance adjusting unit and the second distance adjusting unit to apply an elastic force to the first distance adjusting unit and the second distance adjusting unit toward each other
Implementation Method 3
the first pressing unit and the second pressing unit respectively press a bus bar of the battery module at both sides so that an electrode lead located in a lead slit formed at the bus bar is welded to the bus bar in a closely adhered state
Data Source
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AI summary
Disclosed is a pressing jig for welding, which is installed at one side of a battery module to press a bus bar of the battery module at both sides thereof so that an electrode lead located in a lead slit formed at the bus bar is welded to the bus bar in a closely adhered state. The pressing jig includes a first frame having a first distance adjusting unit and a first pressing unit, and a second frame having a second distance adjusting unit facing the first distance adjusting unit and a second pressing unit facing the first pressing unit. The first frame and the second frame are coupled by a hinge so that a distance between first pressing unit and the second pressing unit is increased when a distance between the first distance adjusting unit and the second distance adjusting unit is decreased, and the distance between first pressing unit and the second pressing unit is decreased when the distance between the first distance adjusting unit and the second distance adjusting unit is increased.