Battery Module Lead Clinching for Simplified Voltage Sensing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing method of connecting electrode leads and voltage sensing members in battery modules is costly and difficult to manage quality due to the use of bus bars and laser welding, which complicates the assembly process.

Innovation Solution

A direct clinching connection is established between electrode leads and voltage sensing members without the use of bus bars, utilizing a support frame with clinching grooves and lead holding members to secure the connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bus bars and laser welding are used to connect electrode leads and voltage sensing members, then reliable electrical connection is achieved, but manufacturing cost increases and assembly complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the bus bar component from the connection structure, directly connecting the voltage sensing member to the electrode lead. This extraction of the intermediate bus bar simplifies the assembly process while maintaining electrical connection reliability through the direct clinching connection between the sensing member and electrode lead.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the functions of electrical connection and voltage sensing into a single integrated structure. The voltage sensing member is directly connected to the electrode lead through clinching, merging what were previously separate connection steps (bus bar attachment and sensing member attachment) into one direct connection, thereby reducing assembly complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If bus bars and laser welding are used to connect electrode leads and voltage sensing members, then reliable electrical connection is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates the bus bar component, removing the associated manufacturing costs for bus bar production, storage, and handling. The direct connection between electrode lead and voltage sensing member reduces material costs and simplifies the supply chain while maintaining connection reliability through the clinching mechanism.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a cost-effective clinching connection method instead of expensive laser welding. The clinching process uses simple mechanical fastening that is cheaper to implement while achieving sufficient connection reliability for the application, reducing overall manufacturing costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If laser welding is used to connect bus bars and voltage sensing members, then strong connection is achieved, but quality management becomes difficult

Engineering Contradiction:

Improveconnection strengthVSAvoidquality management difficulty

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the thermal laser welding process with a mechanical clinching connection system. This substitution eliminates the quality control challenges associated with laser welding (such as heat-affected zones, weld consistency, and equipment calibration) while maintaining strong connection strength through the mechanical interlocking of the clinching structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a simple mechanical clinching method that is easier to control and monitor than laser welding. The clinching process parameters (such as clamping force and positioning) are more straightforward to manage and verify, improving quality management while maintaining adequate connection strength for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 simplifies the assembly process and reduces manufacturing costs by eliminating the need for bus bars and laser welding, while ensuring a strong and reliable electrical connection.

Implementation Method 1

each lead overlapping portion and each sensing part are combined with each other by clinching

Methodology Applied

Scientific EffectClinching: Mechanical Fastener

Data Source

PatentUS12580238B2Battery module in which connection between electrode lead and voltage sensing member is simplified, and battery pack including the same

Publication Date: 2026.03.17 LG ENERGY SOLUTION LTD

AI summary

A battery module includes: a cell stack having battery cells stacked in one direction and at least one lead overlapping portion formed as electrode leads of the battery cells overlap each other; and a voltage sensing member having at least one sensing part directly connected to the at least one lead overlapping portion, wherein each lead overlapping portion and each sensing part are directly combined by clinching.