Battery Module Lead Welding With Tornado-Shaped Weld Spots
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Solution Overview
Problem
The existing welding configurations between electrode leads and bus bars in battery modules have low weldability and are vulnerable to impact and vibration, leading to reduced tensile strength and increased risk of crack propagation.
Innovation Solution
A battery module with a tornado-shaped welding configuration, where multiple spiral welding lines are used to connect electrode leads and bus bars, providing a larger welding area and improved tensile strength, and distributing stress evenly across the welding spot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a linear welding configuration is used to connect electrode leads and bus bars, then the welding process is simple and fast, but the weldability is low and the connection is vulnerable to impact and vibration
Solution Approach 1:
The patent applies curvature by changing the welding configuration from a linear form to a spiral form. The spiral welding line creates a curved, tornado-shaped welding spot that increases the welding area and improves weldability. This curved configuration distributes stress more effectively, making the connection more resistant to impact and vibration while maintaining manufacturing feasibility through automated laser welding processes.
2Area of stationary object
If a linear welding configuration is used, then the welding area is small, but the manufacturing process is simple
Solution Approach 1:
The spiral welding configuration increases the welding area by creating a tornado-shaped welding spot with curved paths. This spiral form naturally expands the welding area compared to a straight line, and the curvature allows for better stress distribution. The manufacturing process remains feasible through automated laser welding systems that can follow the spiral path.
Solution Approach 2:
The patent performs preliminary action by pre-designing the spiral welding configuration before manufacturing. The tornado-shaped welding spot pattern is predetermined and can be programmed into automated welding systems, allowing for consistent reproduction of the complex spiral pattern without requiring manual intervention during the welding process itself.
3Strength
If a linear welding configuration is used, then the welding process is fast, but the tensile strength is low and crack propagation risk is high
Solution Approach 1:
The spiral welding configuration creates a tornado-shaped welding spot that inherently provides higher tensile strength due to the curved, interwoven structure. The spiral pattern distributes mechanical stresses more evenly across the welding area, reducing stress concentration points that would lead to crack initiation and propagation. This geometric configuration naturally enhances strength properties.
Solution Approach 2:
The spiral welding configuration can be viewed as segmented into multiple welding lines that form the tornado shape. These segmented spiral paths work together to create a robust connection, with each segment contributing to the overall strength and crack resistance of the welding joint.
4Reliability
If a linear welding configuration is used, then the welding process is simple, but the connection is vulnerable to impact and vibration
Solution Approach 1:
The curved spiral configuration of the tornado-shaped welding spot provides superior resistance to impact and vibration. The curved paths distribute dynamic loads more effectively than a straight line, and the spiral structure creates multiple load paths that enhance the connection's resilience to mechanical shocks and vibrations encountered in vehicle applications.
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 tornado-shaped welding configuration significantly enhances weldability and tensile strength, stabilizing the electric connection under impact and vibration, and preventing crack growth, thus ensuring reliable performance in applications like electric vehicles.
Implementation Method 1
at least one of the electrode leads is combined and fixed to at least one of another electrode lead and the bus bar, which are contacted by the at least one of the electrode leads, via a welding spot formed in a tornado shape
Data Source
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AI summary
Provided is a battery module in which weldability between electrode leads and/or between an electrode lead and a bus bar is improved. The battery module includes: a cell assembly that includes a plurality of secondary batteries stacked in at least one direction, respectively including electrode leads, and electrically connected to each other via a connection between the electrode leads; and at least one bus bar that includes an electrically conductive material and is electrically connected by contacting the electrode leads of the plurality of secondary batteries, wherein at least one of the electrode leads is combined and fixed to at least one of another electrode lead and the at least one bus bar, which are contacted by the at least one of the electrode leads, via a welding spot formed in a tornado shape.