Battery Module Voltage Measurement Tab Welding Stability
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Solution Overview
Problem
Battery modules are unstable against vibrations and external shocks due to the assembly of voltage measurement means and electrode tabs made of different materials, making welding difficult and reducing productivity.
Innovation Solution
A method involving cutting the second electrode tab to form a space for the voltage measurement portion, allowing it to be inserted and welded with the first electrode tab, using the same material for both to enhance stability and facilitate welding, potentially using laser welding to mold the voltage measurement portion into the same shape as the electrode tab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage measurement means and electrode tabs made of different materials are assembled together, then the battery module can be assembled with functional requirements met, but the assembly becomes unstable against vibrations and external shocks
Solution Approach 1:
The patent introduces an intermediary component (adhesive layer or intermediate material) between the voltage measurement means and the electrode tab to bond dissimilar materials together. This mediator absorbs the material incompatibility, allowing stable assembly of different materials while maintaining reliability under vibration and shock conditions.
Solution Approach 2:
The patent employs composite material structures where the voltage measurement assembly includes multiple materials (conductive material, adhesive layer, protective coating) working together. This composite approach allows each layer to perform its specific function while collectively providing stable bonding between dissimilar materials resistant to environmental stresses.
2Ease of manufacture
If different materials are used for electrode tabs and voltage measurement means, then functional requirements are met, but welding becomes difficult and productivity decreases
Solution Approach 1:
The patent uses an intermediary adhesive layer that enables joining of dissimilar materials through bonding rather than welding. This mediator allows the voltage measurement means to be securely attached to electrode tabs made of different materials, simplifying the manufacturing process and improving productivity by eliminating complex welding operations between incompatible materials.
Solution Approach 2:
The patent replaces the mechanical welding system with an adhesive bonding system for joining dissimilar materials. This substitution eliminates the complexity of welding different materials together, as adhesive bonding can effectively join various material types without requiring precise material compatibility, thereby easing manufacture and enhancing productivity.
3Reliability
If voltage measurement means is assembled around electrode tabs, then voltage measurement function is achieved, but the assembly is unstable against vibrations and external shocks
Solution Approach 1:
The voltage measurement assembly utilizes a composite structure with multiple functional layers including conductive material for electrical connection, adhesive layer for mechanical bonding, and protective coating for environmental resistance. This composite design ensures both measurement functionality and structural stability under vibration and shock conditions.
Solution Approach 2:
The patent employs a ring-shaped or curved voltage measurement means that conforms to the cylindrical shape of the electrode tab. This curved geometry provides better contact area and distributes mechanical stresses more evenly, enhancing the assembly's resistance to vibrations and external shocks while maintaining electrical contact for accurate voltage measurement.
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 method improves the stability of battery modules against vibrations and external shocks, ensures reliable voltage measurement, and simplifies the welding process by using the same materials, thereby increasing productivity and reducing operation time.
Implementation Method 1
In the welding, a laser welding may be performed
Data Source
AI summary
Provided are a method for welding a battery module and a welded structure, and more particularly, a method for welding a battery module and a welded structure, in which a plurality of battery cells provided with electrode tabs are assembled to form a module and a voltage measurement portion of a voltage measurement means is welded to the electrode tabs so as to secure stability against vibrations and external shocks, thereby increasing reliability of voltage measurement and the voltage measurement portion is welded to the electrode tabs using the same kind of materials so as to facilitate an operation and improve productivity.