Battery Cell Lead Coupling Without Welding or Excessive Bending
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Solution Overview
Problem
Existing methods for connecting electrode leads in battery cells often result in damage due to bending and welding, which can compromise the integrity of the leads.
Innovation Solution
A connection member comprising a pair of first and second connection members with fixing and catching portions, made of insulating materials, that allow for electrical connection without welding, ensuring the electrode leads remain unbent and in tight contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent and welded to bus bar, then electrical connection between battery cells is achieved, but electrode leads are damaged by mechanical deformation and welding heat
Solution Approach 1:
The patent introduces a connection member as an intermediary component between the electrode leads and bus bar. This connection member includes a fixing portion that contacts the electrode leads and a catching portion that engages with the bus bar, thereby mediating the connection process without requiring direct bending or welding of the electrode leads themselves
Solution Approach 2:
The patent replaces the traditional welding process with a mechanical coupling system. The connection member uses a fixing portion with a pressing element that applies mechanical pressure to secure the electrode leads in place, substituting the thermal welding process with a cold-press mechanical fastening mechanism
2Reliability
If electrode leads are clamped by bus bar assembly and welded, then electrical connection is maintained, but welding heat damages the electrode leads
Solution Approach 1:
The patent replaces the welding process with a purely mechanical fastening system. The fixing portion includes a pressing element that mechanically clamps the electrode leads against the bus bar, eliminating the need for welding heat while maintaining stable electrical connection through continuous mechanical pressure
Solution Approach 2:
The connection member acts as a mediator that separates the electrode leads from direct exposure to harmful welding processes. The fixing portion contacts the electrode leads gently without heat, while the catching portion secures the connection to the bus bar, thereby protecting the electrode leads from thermal damage
3Reliability
If connection member uses insulating material for fixing and catching portions, then electrode leads are protected from damage, but electrical connection efficiency may be reduced
Solution Approach 1:
The patent applies local quality by making only the portions of the connection member that contact the electrode leads (the fixing portion) from insulating material, while other parts of the connection system can be conductive. This localized insulation protects the electrode leads where needed without compromising overall electrical connection efficiency
Data Source
AI summary
Disclosed are a connection member configured to perform electrical connection between electrode leads, wherein the connection member includes a pair of a first connection member and a second connection member, one of the first connection member and the second connection member is provided with a fixing portion configured to perform connection therebetween, the other of the first connection member and the second connection member is provided with a catching portion configured to allow the fixing portion to be fastened thereto, the electrode leads are physically coupled to each other without welding, and a process of excessively bending the electrode leads so as to be coupled to bus bars is omitted, whereby it is possible to improve safety of the electrode leads, and a battery cell stack including the same.