Rib-Supported Bus Bar Frame for Battery Module Welding Rigidity

Solution Overview

Problem

Welding defects occur during the connection of bus bars to electrode leads in battery modules due to the design of the bus bar or bus bar frame structure, necessitating an improved welding structure to enhance rigidity and prevent interference during the welding process.

Innovation Solution

A battery module design featuring a bus bar frame with ribs that support the bus bar, including a base bottom portion and first rib portions, and a half-blanking shape on the bus bar to prevent interference with bending blades, ensuring proper welding contact and rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the bus bar frame structure is simplified for ease of manufacture, then manufacturing complexity is reduced, but welding rigidity deteriorates causing welding defects

Engineering Contradiction:

Improvebus bar frame manufacturingVSAvoidwelding quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bus bar frame is segmented into a base bottom portion and multiple rib portions that protrude upward. This segmentation allows the frame to be manufactured as a single integrated piece while providing distinct functional zones: the base for structural support and the ribs for localized welding support, thereby maintaining manufacturing simplicity while improving welding rigidity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rib portions extend vertically from the base bottom portion, adding a height dimension to the otherwise planar bus bar frame structure. This vertical dimensionality provides welding support at elevated positions without increasing the horizontal footprint or complicating the manufacturing process, resolving the contradiction between structural rigidity and manufacturing simplicity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If the bus bar frame structure is enhanced to improve welding rigidity, then welding quality is improved, but device complexity increases

Engineering Contradiction:

Improvewelding qualityVSAvoidbus bar frame structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bus bar frame is segmented into a base bottom portion and multiple rib portions that protrude upward. This segmentation allows the frame to be manufactured as a single integrated piece while providing distinct functional zones: the base for structural support and the ribs for localized welding support, thereby maintaining manufacturing simplicity while improving welding rigidity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rib portions are strategically positioned at specific locations where welding support is needed, rather than uniformly distributing structural reinforcement throughout the entire frame. This localized quality enhancement provides welding rigidity precisely where required without unnecessarily increasing overall device complexity.

Inventive Principle:

Principle #3Local quality

3Strength

If the bus bar is supported at multiple points to prevent deformation, then welding rigidity is improved, but the structure becomes more complex

Engineering Contradiction:

Improvebus bar support rigidityVSAvoidbus bar frame structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The bus bar frame is segmented into a base bottom portion and multiple rib portions that protrude upward. This segmentation allows the frame to be manufactured as a single integrated piece while providing distinct functional zones: the base for structural support and the ribs for localized welding support, thereby maintaining manufacturing simplicity while improving welding rigidity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multiple support functions are merged into a single integrated bus bar frame structure that combines the base bottom portion with multiple rib portions. This unified structure provides multi-point support for the bus bar without requiring separate support components, thereby improving rigidity while minimizing structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 rib-supported bus bar frame enhances welding rigidity and prevents welding defects by minimizing interference with bending blades, ensuring reliable electrical connections between electrode leads and bus bars.

Implementation Method 1

the rib portion supports the bus bar, thereby being able to enhance welding rigidity

Methodology Applied

Scientific EffectRigidity:

Implementation Method 2

improve the design of the bus bar or bus bar frame... the rib portion supports the bus bar... preventing interference with bending blades

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 3

the welding process can proceed... the bent portion of the electrode lead is welded to the bus bar

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS12476330B2Battery module and battery pack including the same

Publication Date: 2025.11.18 LG ENERGY SOLUTION LTD

AI summary

A battery module according to one embodiment of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked, a bus bar frame connected to the battery cell stack, an electrode lead protruding from the battery cell stack and passing through a lead slot of the bus bar frame, and a bus bar electrically connected to the electrode lead, wherein the bus bar frame includes a base bottom portion and a first rib portion protruding from the base bottom portion, and wherein the first rib portion supports the bus bar.