Battery Module Sensing Wire Harness Direct Bonding
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Solution Overview
Problem
Conventional battery modules face high production and process costs due to complex bonding processes and space inefficiencies in connecting voltage sensing wire harnesses to cell leads, which also risk deformation during welding.
Innovation Solution
A battery module design featuring a sensing wire harness with a directly bonded connecting terminal to the cell lead, using ultrasonic or laser welding, and a connector fixed with a screw member, where the cell lead is formed by overlapping thin slices to minimize deformation and eliminate separate connection metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate bus bar is used to connect the sensing circuit to the cell lead, then the electrical connection is reliable, but the production cost increases and space utilization decreases
Solution Approach 1:
The patent merges the bus bar function with the cell lead by forming an integrated lead structure that combines both the current-carrying lead and the voltage sensing connection into a single component. This eliminates the need for separate bus bars while maintaining reliable electrical connection for both current collection and voltage sensing.
Solution Approach 2:
The cell lead is designed to serve multiple functions: it acts as both the current collection lead and the voltage sensing connection point. The lead structure includes a lead body and a lead extension that can be directly connected to the sensing wire, making the lead universal for both power and signal functions.
2Strength
If a complex bonding process is used to connect the sensing wire harness to the cell lead, then the connection strength is sufficient, but the production cost and process complexity increase
Solution Approach 1:
The patent extracts the complex bonding process by采用ing a direct welding connection between the sensing wire and the cell lead extension. This eliminates intermediate components and complex assembly steps, achieving strong mechanical and electrical connection through a single welding operation that reduces both process complexity and production cost.
3Reliability
If a separate metal connection component is used, then the electrical conductivity is high, but the material cost and manufacturing complexity increase
Solution Approach 1:
The patent combines the function of separate metal connection components into the cell lead itself. The lead extension is formed from the same material as the cell lead, ensuring high electrical conductivity while eliminating the need for additional metal components, thereby reducing material cost and manufacturing complexity.
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 simplifies the assembly process, reduces material and production costs, enhances space utilization, and prevents deformation of the cell lead during welding.
Implementation Method 1
The connecting terminal of the sensing wire harness may be bonded to the cell lead via welding.
Data Source
AI summary
Provided is a battery module including: a cell assembly in which a plurality of cells are arranged at a predetermined interval, wherein each of the plurality of cells includes a cell lead; a sensing wire harness disposed around the cell lead and including a connecting terminal corresponding to the cell lead, wherein the connecting terminal is directly bonded to the cell lead; and a connector connected to the sensing wire harness by being fixed at one side of the cell assembly.