Battery Module Collector Plate With Dual Connection Terminals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Welding failures between electrodes and connection terminals in battery modules lead to reduced yield rates and increased manufacturing costs due to contamination and other errors.
Innovation Solution
A battery module design featuring a collector plate with both welded and non-welded connection terminals, where only the first connection terminal is initially welded to the electrode, allowing for re-welding with the second terminal if necessary, thereby minimizing yield reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection terminals are welded to electrodes, then electrical connection is established, but welding failures occur due to contamination reducing yield rate
Solution Approach 1:
The patent applies preliminary action by pre-welding only one connection terminal to the electrode before battery assembly, rather than welding all terminals. This preparatory welding step allows the battery to be assembled and tested before completing the welding of remaining terminals, enabling early detection of welding failures without compromising the entire product
Solution Approach 2:
The welding process is segmented into multiple stages: pre-welding of at least one connection terminal before battery assembly, and post-welding of remaining terminals after assembly. This segmentation allows independent optimization and quality control of each welding stage, reducing the impact of welding failures on overall yield rate
2Reliability
If all connection terminals are welded before assembly, then electrical connection is ensured, but welding failures cause complete product rejection
Solution Approach 1:
The patent performs preliminary welding of at least one connection terminal to the electrode before battery cell assembly, ensuring that critical electrical connections are established in advance. This preliminary action provides manufacturing flexibility by allowing post-assembly welding of remaining terminals and enabling re-welding of failed connections without discarding the entire product
Solution Approach 2:
The welding process is made dynamic and adaptable by allowing different welding sequences and timing. At least one terminal is welded before assembly, while other terminals can be welded after assembly, enabling the manufacturing process to adapt to detected welding failures through re-welding operations
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 approach effectively suppresses the reduction in yield rate even when welding failures occur, maintaining product quality and reducing manufacturing costs by enabling re-welding opportunities.
Implementation Method 1
the connection terminals and the electrodes are connected by resistance welding, for example
Data Source
AI summary
A battery module includes: a plurality of battery cells held in a case; and a collector plate disposed on one side or the other side of the plurality of battery cells. The collector plate includes connection terminals connected to a collector plate main body so that the plurality of connection terminals are disposed to face an electrode provided in each of the battery cells. In at least one of the electrodes, the plurality of the connection terminals facing the at least one electrode include a first connection terminal welded to the electrode and a second connection terminal not welded to the electrode.