Battery Module Busbar Structure for Multi-Point Electrode Lead Welding
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Solution Overview
Problem
Conventional battery modules face challenges in maintaining a compact structure and minimizing cost due to increased electrode lead cutting and the need for higher welding machine specifications as the number of cell terraces and battery cells grows.
Innovation Solution
The battery module incorporates a busbar frame connected to a battery cell stack, with electrode leads overlapping the busbar and featuring at least two welding points. This design reduces unnecessary increases in welding machine specifications and stabilizes welding quality, while minimizing electrode lead cutting and maintaining a compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of cell terraces and battery cells is increased to achieve larger capacity, then the battery capacity is improved, but the number of electrode leads increases causing increased cutting loss and higher device complexity
Solution Approach 1:
Multiple electrode leads of the same polarity are merged and overlaid on a single busbar, forming a bundled structure that is welded at multiple points. This consolidates multiple individual connections into one integrated connection point, reducing the number of separate electrode leads needed while maintaining electrical connectivity for all cells.
Solution Approach 2:
The busbar is divided into multiple welding portions along its length, with each welding portion connecting to the bundled electrode leads at different locations. This segmentation of the welding process allows multiple electrode leads to be connected simultaneously at different points along the busbar, reducing the need for multiple separate busbars and connections.
2Device complexity
If multiple electrode leads are connected to the same busbar to reduce complexity, then device complexity is reduced, but welding machine specifications must be increased to handle multiple leads simultaneously
Solution Approach 1:
The welding process is segmented into multiple independent welding portions along the busbar length. Each welding portion can be welded separately using standard welding machines, avoiding the need for high-power machines capable of welding all electrode leads simultaneously. The segmentation distributes the welding load across multiple lower-power operations.
Solution Approach 2:
Instead of welding all electrode leads at a single point with excessive welding power, the solution applies partial welding action at multiple distributed points along the busbar. Each welding portion uses moderate power sufficient for that local connection, achieving the same overall connectivity without requiring peak power that would necessitate upgraded welding machine specifications.
3Reliability
If electrode leads are extended to reach the busbar, then connectivity is improved, but the amount of electrode lead cutting increases resulting in cost loss
Solution Approach 1:
Electrode leads from adjacent cells are preliminarily positioned and overlaid on the busbar before the welding process. This preliminary arrangement allows the leads to be aligned and secured in their final positions, ensuring proper connectivity while minimizing the length of lead that needs to be cut and discarded, as the overlay configuration optimizes material utilization.
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
The solution enables stable management of welding quality, reduces cost loss by minimizing electrode lead cutting, and achieves a compact battery module structure by optimizing the gap between the busbar frame and the battery cell stack.
Implementation Method 1
at least two welding points between the busbar and the electrode leads are formed
Data Source
AI summary
Discussed are a battery module and a method of manufacturing the battery module. A battery module according to an embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked, a busbar frame connected to the battery cell stack and having a plurality of busbars, cell terraces each protruding from battery cells adjacent to each other among the plurality of battery cells included in the battery cell stack, and electrode leads each protruding from the cell terraces and having the same polarity, wherein the electrode leads overlap with the same busbar among the plurality of busbars, and include at least two welding points at overlapping portions of the same busbar and the electrode leads.