Battery Cell Sampling Assembly With Laser-Welded Support Base

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Solution Overview

Problem

The existing sampling assemblies for battery cells are inefficient to assemble and prone to deformation or damage during the assembly process, affecting the yield of final products due to the need for downward pressure and complex welding sequences.

Innovation Solution

A sampling assembly that uses a support base with a conductive connecting piece and bonding member, connected via a lead, which eliminates the need for downward pressure and simplifies the assembly process using only a laser welding device, reducing the risk of deformation and improving assembly efficiency and yield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the sampling assembly is assembled using the related art method with downward pressure, then the assembly can be completed, but the assembly process is complex and time-consuming

Engineering Contradiction:

Improveassembly efficiencyVSAvoidassembly process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The sampling assembly is divided into separate components: a sampling member with lead, a support base with conductive connecting piece, and a bonding member. These segmented parts can be prepared independently and assembled through simple laser welding, eliminating the need for complex downward pressure application and multi-step welding processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bonding member is pre-positioned to connect the conductive connecting piece to the battery cell before final assembly. This preliminary action simplifies the overall assembly process by pre-establishing critical connections, allowing the sampling member to be integrated through a single laser welding operation rather than complex sequential steps.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If downward pressure is applied during assembly, then the sampling assembly can be secured, but deformation or damage occurs affecting yield

Engineering Contradiction:

Improveassembly yieldVSAvoiddeformation and damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The mechanical downward pressure system is replaced with a laser welding-based bonding system. The bonding member is secured through laser welding between the conductive connecting piece and the battery cell, eliminating the need for mechanical compression that causes deformation and damage, thereby improving assembly yield.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The assembly method transitions from mechanical pressure (force parameter) to thermal energy (temperature parameter) for bonding. Laser welding uses controlled thermal energy to create strong joints without the deforming effects of mechanical pressure, preserving the integrity of the battery cell and sampling components.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If multiple welding devices and downward pressure are used, then the assembly can be completed, but the assembly time increases

Engineering Contradiction:

Improveassembly speedVSAvoidassembly process simplification

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

Multiple welding operations are merged into a single laser welding process. The bonding member connects both the conductive connecting piece and the battery cell through one integrated laser welding step, eliminating the need for multiple welding devices and sequential operations, thereby speeding up assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laser welding device performs multiple functions: it bonds the bonding member to both the conductive connecting piece and the battery cell in one operation. This multi-functional approach replaces the need for specialized welding devices and complex positioning mechanisms, simplifying automation while improving speed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enhances assembly efficiency and product yield by eliminating the need for downward pressure and reducing the complexity of the assembly process, while ensuring a stable and secure electrical connection between the sampling member and the battery cell.

Implementation Method 1

only a laser welding device is used to connect the bonding member to the conductive connecting piece and to connect the bonding member to the battery cell

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS20240021897A1Sampling assembly and manufacturing method thereof, battery, and electric device

Publication Date: 2024.01.18 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A sampling assembly for a battery including at least two battery cells arranged along a first direction, includes a sampling member configured to transmit sample signals and having a lead, a support base configured to provide support between two of the battery cells adjacent along the first direction, a conductive connecting piece provided on the support base and connected to the lead, and a bonding member. One end of the bonding member is for connecting to the conductive connecting piece, and the other end of the bonding member is for connecting to the battery cell to collect sample signals of the battery cell.