Battery Module Pressing Jig for Straight Lead-to-Bus Bar Welding
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Solution Overview
Problem
Conventional battery module manufacturing processes require bending of electrode leads, which complicates the process and reduces bonding strength due to a smaller bonding area, increasing the risk of product failure.
Innovation Solution
A pressing jig apparatus that allows electrode leads to be welded directly to a bus bar without bending, using a rotatable frame with chamfered pressing tips and an elastic member to ensure close contact and prevent weld pool adherence, along with a lead protrusion-preventing unit to maintain the leads below the bus bar surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrode lead is bent to be in close contact with the bus bar, then the electrode lead can be positioned on the bus bar for welding, but the process becomes complicated and the bonding area is reduced
Solution Approach 1:
The patent extracts the bending operation from the electrode lead preparation process. Instead of bending the electrode lead to achieve contact, the pressing jig directly presses the straight electrode lead against the bus bar, eliminating the bending step while maintaining effective contact for welding.
Solution Approach 2:
The patent replaces the mechanical bending operation with a pressing operation. The pressing jig applies mechanical force directly to press the electrode lead against the bus bar surface, substituting the complex bending mechanism with a simpler pressing action that achieves the same contact objective.
2Ease of operation
If the electrode lead is bent to contact the bus bar, then positioning is achieved, but the bonding area between electrode lead and bus bar is reduced
Solution Approach 1:
The patent removes the bending step that was causing reduction in bonding area. By pressing the straight electrode lead against the bus bar, the full surface area of the electrode lead can be utilized for bonding, maximizing the bonding area and strength.
Solution Approach 2:
The pressing jig performs preliminary positioning and pressing of the electrode lead before welding. This preliminary action ensures that the electrode lead is correctly positioned and maintains optimal contact pressure during the welding process, maximizing bonding area and strength.
3Manufacturing precision
If the pressing tip contacts the electrode lead at the welding position, then close contact is achieved, but the weld pool adheres to the pressing jig
Solution Approach 1:
The pressing tip is designed with different surface properties at different locations. The portion that contacts the electrode lead has high precision for positioning, while the portion near the welding area has low surface energy or specific geometry to prevent weld pool adherence, creating local quality differences to solve the contradiction.
Solution Approach 2:
The patent converts the potential harm of weld pool adherence into a benefit by designing the pressing tip geometry or surface treatment to actively repel or prevent weld pool contact. The pressing tip's specific shape or coating material causes the weld pool to naturally avoid adhering to it, turning a potential problem into a solution.
4Volume of moving object
If the electrode lead is shortened for pouch-type cells, then the cell thickness is reduced, but the bonding area is reduced and bonding strength is lowered
Solution Approach 1:
The patent replaces the bending mechanism with direct pressing, allowing the shortened electrode lead to maintain its full length for bonding without losing effective bonding area through bending. The pressing action ensures adequate contact pressure despite the reduced lead length, maintaining bonding strength while accommodating thinner pouch-type cells.
Solution Approach 2:
The pressing jig applies preliminary pressing force to the shortened electrode lead before welding, ensuring that the reduced-length lead achieves optimal contact with the bus bar. This preliminary action compensates for the reduced bonding area that would otherwise result from the shorter lead length.
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 electrode leads to be welded in an unbent state, reducing the risk of breakage and preventing weld pool contamination of the pressing jig, thus enhancing bonding strength and manufacturing efficiency.
Implementation Method 1
at least one elastic member connected between the first frame and the second frame to apply a force so that the first frame and the second frame move closer to each other
Data Source
AI summary
Discussed is a battery module manufacturing system, which includes a battery module having a cell stack formed by stacking a plurality of battery cells, a module case configured to accommodate the cell stack and a bus bar frame configured to cover an opening at one side of the module case; a fixing frame coupled to one side of the battery module so that the bus bar frame is exposed to the outside; and at least one pressing jig apparatus coupled onto the fixing frame and configured to press electrode leads of the plurality of battery cells so that the electrode leads are welded in close contact with both sides of a bus bar provided to the bus bar frame.