Battery Module Layered Electrode Lead Welding
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Solution Overview
Problem
The existing battery module welding process is affected by the difference in melting points of electrode leads, leading to excessive plastic flow and voids, which compromises welding strength and safety due to the need for varying welding temperatures for different materials.
Innovation Solution
A battery module design where the first electrode lead, with a higher melting point, is arranged in a layered construction with the second electrode lead, allowing for connection points that only require a welding temperature sufficient for the low melting point electrode lead, avoiding the need for high temperatures that can cause voids and improving connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different welding temperatures are used for welding electrode leads with different melting points, then welding quality for each material can be optimized, but welding process complexity increases and multiple weld layers affect each other causing voids
Solution Approach 1:
The patent applies local quality by arranging electrode leads with different melting points in a layered construction where the higher melting point electrode lead is positioned above the lower melting point electrode lead. This spatial arrangement allows each electrode lead to be welded at its optimal temperature without interfering with others, as the welding zones are separated in the vertical direction. The connection points are strategically positioned to ensure proper welding of each layer at its specific temperature requirement.
Solution Approach 2:
The patent resolves the temperature conflict by transitioning from a planar welding arrangement to a three-dimensional layered construction. By stacking electrode leads in the vertical dimension with different melting points at different heights, the patent enables simultaneous welding at multiple temperatures without the weld layers interfering with each other. This dimensional change separates the welding processes in space, eliminating the mutual interference that occurs in two-dimensional arrangements.
2Strength
If high welding temperature is used to weld high melting point electrode leads, then welding strength is improved, but excessive plastic flow and voids occur in low melting point electrode leads
Solution Approach 1:
The patent segments the welding process by separating electrode leads with different melting points into distinct vertical layers. The higher melting point electrode lead (e.g., copper) is positioned in the upper layer, while the lower melting point electrode lead (e.g., aluminum) is positioned in the lower layer. This segmentation allows each material to be welded at its appropriate temperature without the high temperature affecting the lower melting point material, thus preventing excessive plastic flow and void formation while maintaining welding strength.
Solution Approach 2:
The layered construction acts as an intermediary structure that mediates between the conflicting temperature requirements of different electrode lead materials. By introducing this vertical layering arrangement, the patent creates separate welding zones where each material can be joined at its optimal temperature. The spatial separation in the layered structure prevents thermal interference between materials with different melting points, resolving the contradiction between achieving strong welds and avoiding damage to sensitive materials.
3Volume of stationary object
If electrode leads are arranged in a compact configuration to save space, then battery module density is improved, but welding accessibility and connection reliability deteriorate
Solution Approach 1:
The patent utilizes the vertical dimension to arrange electrode leads in stacked layers, allowing compact horizontal spacing while maintaining adequate vertical separation for welding operations. This three-dimensional arrangement achieves high space utilization by stacking electrode leads vertically rather than spreading them horizontally, while the vertical layering ensures that connection points remain accessible and welding quality is not compromised by overcrowding.
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 enhances welding strength and connection reliability by eliminating the need for high temperatures that can cause excessive plastic flow and voids, ensuring stable connections between electrode leads with different melting points.
Implementation Method 1
each of the connection points is adapted to electrically connect one of the first electrode leads of the first battery unit to at least one of the second electrode leads of the second battery unit
Data Source
AI summary
The present disclosure relates to a battery module comprising a first battery unit and a second battery unit, each of which comprises N secondary batteries, N is an integer greater than or equal to 2, and each secondary battery comprises a first electrode lead and a second electrode lead having opposite polarities. The first electrode lead has a melting point higher than that of the second electrode lead, and N first electrode leads of the first battery unit and N second electrode leads of the second battery unit are arranged to form a layered construction. The battery module has a plurality of connection points distributed in the layered construction, the number of which is greater than or equal to N, and each connection point is adapted to electrically connect one first electrode lead of the first battery unit to at least one second electrode lead of the second battery unit.