Battery Pack Bus Bar Redundancy for Welding Failure Mitigation
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Solution Overview
Problem
Existing battery packs face issues with electrode damage and high manufacturing losses due to welding failures, particularly in connecting multiple battery cells, which limits their efficiency and reliability.
Innovation Solution
A battery pack design featuring a configuration of battery modules with bus bars that connect battery assemblies and modules in series, using a combination of resistance welding and laser welding to minimize the impact of welding failures, with bus bars arranged to facilitate efficient electrical connections and heat dissipation, allowing for the connection of battery cells in a parallel and series configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If normal welding is used to connect battery cells, then manufacturing process is simple, but welding failure causes electrode damage and high manufacturing losses
Solution Approach 1:
The patent applies beforehand cushioning by providing a backup connection terminal that can be used if the primary welding connection fails. The battery module includes both a first connection terminal (primary) and a second connection terminal (backup), where the second terminal is prepared in advance to compensate for potential welding failures, preventing electrode damage without complicating the primary manufacturing process
Solution Approach 2:
The patent changes the connection parameter from a single welding point to multiple connection terminals. By providing both first and second connection terminals with different connection methods (welding for primary, alternative method for backup), the system transforms the connection reliability parameter while maintaining manufacturing feasibility
2Reliability
If backup connection terminal is added to prevent welding failure, then reliability improves, but device complexity increases
Solution Approach 1:
The patent segments the connection function into primary and backup terminals. The first connection terminal handles normal welding operations, while the second connection terminal serves as a dedicated backup. This segmentation allows the system to improve reliability through redundancy without requiring complete redesign of the entire connection system
Solution Approach 2:
The backup connection terminal acts as a disposable or standby component that remains unused during normal operation but provides critical reliability assurance when needed. This approach improves reliability while minimizing complexity, as the backup terminal is a simple additional component rather than a complex active system
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 design reduces manufacturing losses by allowing for the replacement of individual battery modules or cells rather than entire packs, enhances energy density, and improves workability by simplifying wiring connections and heat management, while maintaining a compact size.
Implementation Method 1
the connection portion includes a solidification portion that is solidified from a molten body
Implementation Method 2
using a combination of resistance welding and laser welding to minimize the impact of welding failures
Implementation Method 3
using a combination of resistance welding and laser welding to minimize the impact of welding failures
Data Source
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AI summary
Provided is a battery pack (1) in which a bus bar (30) for modules is provided on one side of a plurality of battery modules (20) in a height direction, and connects the battery modules (20) that are adjacent to each other among the plurality of battery modules (20), in series. In addition, the bus bar (30) for modules includes a first bus bar piece (31) that is provided in a battery module (20) on one side between the battery modules (20) that are adjacent to each other, and a second bus bar piece (32) that is provided in a battery module (20) on the other side and is different from the first bus bar piece (31), and a connection portion (33) that connects the first bus bar piece (31) and the second bus bar piece (32).