Battery Module Bus Bar Elastic Deformation for Welding

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Solution Overview

Problem

Conventional battery modules face challenges in maintaining stable electrical connections between electrode leads and bus bars, leading to potential short circuits, separation issues, and reduced productivity due to complex welding processes, especially in compact designs for vehicles.

Innovation Solution

A battery module design where electrode leads protrude from secondary batteries and are bonded to bus bars with a main frame and bonding plates, eliminating the need for bending and allowing for straight insertion, enhancing weldability and space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode leads are bent to contact the bus bar for stable bonding, then connection stability is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveconnection stabilityVSAvoidbonding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of bending the electrode lead to contact the bus bar, the invention inverts the approach by making the bus bar adapt to the electrode lead's position. The bus bar is designed with a bending section that can elastically deform to contact the protruding electrode lead end, eliminating the need to bend the electrode lead itself.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention changes the physical state of the bus bar by introducing elastic deformation capability through a bending section. This allows the bus bar to dynamically adjust its shape to maintain stable contact with the electrode lead, improving connection reliability without increasing electrode lead complexity.

Inventive Principle:

Principle #35Parameter changes

2Area of stationary object

If electrode leads are bent for bonding, then contact area is increased, but manufacturing time and productivity are reduced

Engineering Contradiction:

Improvecontact areaVSAvoidmanufacturing efficiency

Core Design Contradiction:

Area of stationary objectVSProductivity

Solution Approach 1:

The invention reverses which component is bent - the bus bar bends instead of the electrode lead. This eliminates time-consuming electrode lead bending operations while the bus bar's elastic bending section provides sufficient contact area for stable bonding.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The bus bar is pre-designed with a bending section that has predetermined elastic deformation characteristics. During assembly, this bending section automatically deforms to the required shape to contact the electrode lead, eliminating the need for on-site bending operations and reducing manufacturing time.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If electrode leads protrude straight without bending, then manufacturing simplicity is improved, but contact area with bus bar is reduced

Engineering Contradiction:

Improveassembly simplicityVSAvoidbonding surface area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

Instead of bending the electrode lead to increase contact area, the invention makes the bus bar bend to the electrode lead. The bus bar's bending section provides the necessary contact area while the electrode lead remains straight and easy to manufacture.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The bus bar incorporates a dynamic bending section that can elastically deform during assembly to achieve optimal contact area with the electrode lead. This dynamic adaptation allows sufficient bonding surface area without requiring the electrode lead to be pre-bent or complexly shaped.

Inventive Principle:

Principle #15Dynamics

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 design ensures reliable electrical connections, reduces manufacturing time and cost, and improves welding efficiency by eliminating the need for bending operations and providing a larger contact area for bonding, while preventing interference and damage during assembly.

Implementation Method 1

the connection portions may be welded to maintain the connected state

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11342632B2Battery module

Publication Date: 2022.05.24 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a plurality of pouch-type secondary batteries arranged to be stacked in at least one direction, each secondary battery having an electrode lead, and a bus bar made of an electrically conductive material and bonded to at least two electrode leads of corresponding secondary batteries to electrically connect the corresponding secondary batteries to each other. Each bonded electrode lead may be configured to protrude from the corresponding secondary battery in a front and rear direction, and at least one of left and right side surfaces of each bonded electrode lead may be bonded to the bus bar.