Battery Lead Bending Sequence for Precise Busbar Frame Attachment
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Solution Overview
Problem
Existing methods for bending leads in battery cells can lead to deformation and decreased bending quality, which is a concern for maintaining the integrity and stability of medium-large battery devices.
Innovation Solution
A lead bending method that involves positioning a bending tool perpendicular to the lead, tilting it towards the busbar frame assembly, attaching the lead to the frame by pressing, and sliding the tool to ensure stable attachment, minimizing deformation by controlling the distance and overlap with the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a general bending method is used to bend the lead, then the bending process is simple, but deformation of the battery and decreased bending quality occur
Solution Approach 1:
The bending process is divided into multiple sequential steps: positioning the bending tool at a specific distance from the busbar frame assembly, tilting the lead to a predetermined angle, pressing the lead to attach it to the frame, and sliding the tool along the lead. This segmentation of the bending operation into controlled stages ensures precise positioning and force application, preventing battery deformation while achieving high bending quality.
Solution Approach 2:
The bending tool is positioned at a predetermined distance (half the length of the protruding lead) from the busbar frame assembly before the bending operation begins. The lead is also tilted to a predetermined angle before pressing. These preliminary positioning actions ensure that the bending force is applied at the optimal location and angle, preventing deformation while achieving accurate bending results.
2Manufacturing precision
If bending force is applied directly to the lead near the busbar frame assembly, then bending precision is improved, but the force required increases and may cause deformation
Solution Approach 1:
Instead of applying bending force directly along the length of the lead (one dimension), the bending tool is positioned perpendicular to the lead at a specific distance from the busbar frame assembly (adding a second dimension). The lead is tilted at a predetermined angle, and the tool presses in a direction that combines vertical and horizontal components. This dimensional approach distributes the force more effectively, reducing the total force required while maintaining bending precision.
Solution Approach 2:
The bending tool acts as an intermediary between the bending mechanism and the lead. By positioning the tool at a predetermined distance from the busbar frame assembly and tilting the lead, the tool mediates the force application, distributing it along the lead's length rather than concentrating it at a single point. This reduces the peak force required while achieving the desired bend.
3Reliability
If the lead is bent to attach to the busbar frame assembly, then electrical connection is achieved, but battery deformation may occur
Solution Approach 1:
The bending operation is localized to specific regions of the lead, with the bending tool positioned at a predetermined distance from the busbar frame assembly. The lead is tilted and pressed at specific locations rather than along its entire length. This localized approach ensures reliable attachment at the connection point while minimizing stress and deformation in other parts of the battery structure.
Solution Approach 2:
The bending tool is positioned and the lead is tilted to predetermined positions before the pressing operation begins. This preliminary positioning creates a controlled configuration that prevents excessive force from being applied to the battery structure during bending. By pre-positioning the lead at an optimal angle and location, the subsequent pressing action achieves reliable attachment without causing deformation.
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 method reduces the force required for bending, enhances stability, and prevents deformation by ensuring proper attachment of the leads to the busbar frame assembly, thereby maintaining the integrity of the battery cells.
Implementation Method 1
the bending tool may press the busbar frame assembly so that the busbar frame assembly is elastically deformed toward the one side in the first direction
Implementation Method 2
tilting the first lead toward the other side in the second direction by pressing the first lead by moving the bending tool toward the other side in the second direction
Data Source
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AI summary
A method for bending a lead, according to the present invention, is a method for bending a first lead protruding from a battery cell stack positioned on one side of a first direction of a bus bar frame assembly including a bus bar and a bus bar frame for accommodating the bus bar, to the other side of the first direction of the bus bar frame assembly. The method includes the steps of: positioning a bending tool on one side of the first lead in a second direction perpendicular to the first direction; tilting the first lead to the other side in the second direction by pressing the first lead by moving the bending tool to the other side in the second direction; adhering the first lead to the bus bar frame assembly by pressing the first lead by moving the bending tool to one side in the first direction; sliding the bending tool with respect to the first lead by moving the bending tool to the other side in the second direction; and moving the bending tool to the other side in the first direction.