Bus-bar Holder Spacing for Battery Module Welding
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Solution Overview
Problem
The assembly of battery modules is challenging due to the difficulty in connecting bus-bars, which can cause physical issues and heat damage to bus-bar holders, especially when using plastic materials, leading to suboptimal welding processes and appearance of the welding bead.
Innovation Solution
A battery module design featuring a bus-bar holder with a guide portion and a fixing member, where the bus-bar is spaced apart from the holder's circumference, allowing for reduced heat transfer during welding and preventing holder melting, along with a gas exhausting portion to manage shield gas effectively, enhancing workability and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus-bar is connected directly to the bus-bar holder during welding, then electrical connection is achieved, but the bus-bar holder suffers from heat damage and melting
Solution Approach 1:
The patent divides the connection structure into separate functional zones: the bus-bar is spaced apart from the bus-bar holder by a predetermined interval, creating distinct regions for electrical connection and structural support. This segmentation prevents heat from the welding process from directly affecting the holder while maintaining electrical connectivity through the bus-bar's connection to terminal portions.
Solution Approach 2:
The patent introduces an intermediary space (the predetermined interval) between the bus-bar and bus-bar holder. This intermediate region acts as a thermal buffer during welding, allowing the bus-bar to be connected to terminal portions without transferring excessive heat to the holder, thus protecting the holder from heat damage.
2Ease of manufacture
If the bus-bar holder is made of plastic material, then ease of manufacture and cost are improved, but the holder cannot withstand welding heat and melts
Solution Approach 1:
The patent separates the functions of electrical connection and structural support by spacing the bus-bar away from the bus-bar holder. This allows the holder to be made from thermally sensitive materials like plastic that are easy to manufacture, while the bus-bar (made from heat-resistant material) handles the thermal aspects of welding and connection.
Solution Approach 2:
The predetermined interval serves as a thermal intermediary that protects the plastic bus-bar holder from direct exposure to welding heat. This intermediate space enables the use of cost-effective plastic materials for the holder while maintaining the ability to perform welding operations on the bus-bar without damaging the holder.
3Stability of the object's composition
If the bus-bar is positioned close to the bus-bar holder, then structural stability is improved, but welding heat damages the holder and affects appearance
Solution Approach 1:
The patent creates a segmented arrangement where the bus-bar is positioned at a predetermined interval from the bus-bar holder rather than being in direct contact. This spatial segmentation prevents heat-affected zone from reaching the holder, ensuring clean welding beads and professional appearance while maintaining structural integrity through proper positioning and support structures.
4Device complexity
If shielding gas is not properly managed during welding, then welding process is simplified, but short circuits and contamination occur
Solution Approach 1:
The patent extracts and removes shielding gas from the welding area through dedicated exhaust paths. By providing specific gas exhausting portions in the bus-bar holder structure, the system actively removes shielding gas and potential contaminants from the welding zone, preventing short circuits and ensuring high-quality electrical connections without significantly complicating the welding process.
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 the assembly process by reducing thermal influence on the bus-bar holder, preventing damage and improving the external appearance of the welding bead, while ensuring reliable electrical connections and safety through efficient gas management.
Implementation Method 1
the bus-bar being spaced apart from a circumference of the opening of the bus-bar holder by a predetermined interval, allowing for reduced heat transfer during welding and preventing holder melting
Implementation Method 2
The terminal portion of the battery cell and the bus-bar may be bonded through welding
Data Source
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AI summary
A battery module includes a plurality of battery cells arranged in a first direction, each one of the plurality of battery cells having a terminal portion on an upper surface thereof, a bus-bar holder positioned on the plurality of battery cells, the bus-bar holder having an opening exposing terminal portions of the plurality of battery cells, a bus-bar positioned in the opening of the bus-bar holder, the bus-bar being spaced apart from a circumference of the opening of the bus-bar holder by a predetermined interval, and the bus-bar electrically connecting terminal portions of adjacent battery cells among the plurality of battery cells, a guide portion extending along the opening in the first direction, the guide portion extending upward above the opening, and a fixing member on an inner surface of the guide portion.