Battery Pack Electrode Lead Segmentation for Uniform Welding
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Solution Overview
Problem
The existing battery packs face welding defects due to uneven transmission of welding energy when electrode leads are welded to a bus bar, leading to poor weldability between electrode leads and bus bars.
Innovation Solution
The battery pack design includes electrode leads with integrated first and second lead parts and a connection part, where the second lead part overlaps the first lead part, and both are welded to the bus bar using ultrasonic or laser welding, enhancing weldability by increasing the contact area and using a folding groove to facilitate symmetrical folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are welded to bus bar in overlapping state, then connectivity between battery cells is improved, but welding defects occur due to non-uniform energy transmission
Solution Approach 1:
The electrode lead is divided into first and second lead parts that are separately welded to the bus bar at different positions, preventing overlapping during welding and ensuring uniform energy transmission to each welding point
Solution Approach 2:
A connection part is introduced as an intermediary component between the first and second lead parts, allowing the lead parts to be positioned separately for welding while maintaining electrical connectivity through the connection part
2Device complexity
If electrode leads are integrated to simplify structure, then device complexity is reduced, but weldability between electrode lead and bus bar deteriorates
Solution Approach 1:
The integrated electrode lead is segmented into multiple lead parts with distinct welding positions, allowing each part to be welded separately to the bus bar while maintaining the overall integrated structure
Solution Approach 2:
Different regions of the electrode lead are designed with different functions: the lead parts are designed for welding connectivity to the bus bar, while the connection part is designed for lead-to-lead connectivity, optimizing both weldability and structural integration
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 improves connectivity between battery cells and prevents welding defects by ensuring uniform energy distribution and increased contact area during welding, resulting in a more reliable and efficient battery pack.
Implementation Method 1
The first lead part and the bus bar or the second lead part and the first lead part may be coupled to each other through ultrasonic or laser welding
Implementation Method 2
The first lead part and the bus bar or the second lead part and the first lead part may be coupled to each other through ultrasonic or laser welding
Data Source
AI summary
Provided is a battery pack. The battery pack includes a plurality of battery cells, each of which is provided with an electrode tab, an electrode lead including first and second lead parts respectively connected to the electrode tabs of the adjacent battery cells and a connection part connecting the first and second lead parts to each other, and a bus bar to which the first and second lead parts are coupled and connecting the plurality of battery cells to each other in series or parallel.