Battery Module Segmentation for Reliable Welding
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Solution Overview
Problem
Conventional battery modules face challenges in minimizing damage to battery cells during welding, especially when using high-energy ultrasonic welding methods, and lack flexibility in connection methods as the number of stacked cells increases, leading to potential electrical damage and reduced welding device lifespan.
Innovation Solution
The battery module design incorporates multiple electrical connection points with fewer members at each point, allowing for reduced energy usage and enabling various connection methods, such as welding, bolting, or riveting, to prevent damage and improve manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding requiring a large amount of energy is carried out to electrically connect multiple battery cells, then connection reliability is improved, but battery cells may be electrically damaged and the lifespan of welding device is reduced
Solution Approach 1:
The patent divides the battery module into multiple unit modules, each with fewer electrically connected members. This segmentation allows each welding operation to involve fewer components, reducing the energy required per welding point and preventing damage to battery cells while maintaining overall connection reliability through distributed connection points.
2Power
If the number of stacked battery cells is increased to provide high output and large capacity, then power source capability is improved, but thicknesses and widths of electrode terminals and bus bar are increased requiring large amount of energy during welding
Solution Approach 1:
The patent segments the battery module into multiple unit modules with fewer connected members each. This allows the system to achieve high power through multiple small-scale connections rather than one or few large-scale connections, reducing the energy required for welding while maintaining the necessary electrical capacity.
3Strength
If ultrasonic welding is used to electrically connect battery cells, then connection strength is improved, but ultrasonic waves may be transferred to other regions causing electrical damage and battery cells may be attached to welding device
Solution Approach 1:
By dividing the battery module into unit modules with fewer connected members, the patent reduces the concentration of ultrasonic energy at any single location. This segmentation prevents ultrasonic wave transfer to adjacent regions and eliminates the risk of battery cells attaching to the welding device, while still achieving strong connections at each distributed connection point.
4Adaptability or versatility
If multiple battery cells are electrically connected to a bus bar, then electrical connection capability is improved, but the number of electrically connected members increases making welding difficult
Solution Approach 1:
The patent segments the electrical connection system into multiple unit modules, each with a manageable number of connected members. This makes welding easier at each individual connection point while achieving the desired electrical connection capability through the collective arrangement of multiple unit modules with series and/or parallel connections.
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 configuration reduces energy requirements and minimizes damage to battery cells and welding devices, enabling efficient and flexible electrical connections while maintaining structural integrity and safety.
Implementation Method 1
ultrasonic welding requiring a large amount of energy is carried out
Data Source
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Figure 3(a)~3(c)
Figure 4
AI summary
Disclosed herein is a battery module including a plurality of unit modules, based on battery cells which can be charged and discharged, electrically connected to each other, wherein the unit modules are electrically connected to each other in series and/or in parallel or the unit modules are electrically connected to a bus bar in series and/or in parallel, the battery module has two or more electrical connection points, and the number of electrically connected members at each of the electrical connection points is less than the total number of the electrically connected members of the battery module.