Battery Module V-Shaped Connection Bar Two-Sheet Welding
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Solution Overview
Problem
Conventional three-sheet welding methods for battery modules are sensitive to welding conditions and environmental factors, leading to quality issues, restricted welding gaps, and reduced weldability, making it difficult to maintain reliable electrical connections and voltage sensing.
Innovation Solution
A battery module employing two-sheet welding with a sub-bus bar for electrical connections and voltage sensing, where connection terminals are bent and bonded to form a V-shaped cross-section, allowing for reliable electrical connections and voltage sensing even at small gaps, and enabling direct voltage sensing through a connection bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If three-sheet welding is used for voltage sensing, then voltage sensing structure can be integrated, but welding quality becomes difficult to maintain due to sensitivity to welding conditions and environmental factors
Solution Approach 1:
The patent divides the welding process into two separate two-sheet welding operations instead of one three-sheet welding operation. The connection bar is welded to the first cell tab, and then the second cell tab is welded to the connection bar, creating two distinct welding zones that are easier to control and maintain quality than a single three-sheet weld.
Solution Approach 2:
The connection bar serves as an intermediary element between the first and second cell tabs. This intermediate component allows for separate two-sheet welding operations, improving weld quality control while still achieving the integrated voltage sensing function that would otherwise require three-sheet welding.
2Adaptability or versatility
If three-sheet welding is used, then voltage sensing can be implemented, but welding gap between cells must be at least 5 mm which restricts space utilization
Solution Approach 1:
By segmenting the welding into two separate two-sheet welding operations, the required welding gap is reduced from 5 mm to a smaller gap suitable for two-sheet welding. This allows better space utilization while maintaining voltage sensing capability through the connection bar structure.
3Adaptability or versatility
If three-sheet welding is used, then integrated voltage sensing structure is achieved, but weldability is reduced and welded portions are separated
Solution Approach 1:
The patent segments the complex three-sheet welding into two simpler two-sheet welding operations. This segmentation improves weldability by reducing the complexity of each welding operation, ensuring better adhesion and fewer defects, while the connection bar maintains the integrated voltage sensing structure.
Solution Approach 2:
The connection bar acts as an intermediary that connects the first and second cell tabs through separate two-sheet welding operations. This intermediary approach ensures reliable welding at each interface while maintaining the integrated voltage sensing function, avoiding the separation issues that occur in three-sheet welding.
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 solution enhances the reliability of electrical connections and voltage sensing, reduces cell thickness and resistance, and prevents welding deterioration and defects, thereby maximizing output and discharge power while ensuring quality.
Implementation Method 1
The laser welding method is generally based on fusing of a meta material using laser energy
Data Source
AI summary
A battery module includes: a first battery cell and a second battery cell which have connection terminals, respectively, and are stacked to allow the connection terminals to face each other; and a connection bar having a first surface and a second surface interconnected to form a V-shaped cross-section. The connection terminal of the first battery cell is bonded to the first surface and the connection terminal of the second battery cell is bonded to the second surface.