Bus Bar Pressing Mechanism for Battery Module Welding
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Solution Overview
Problem
Conventional battery module production requires manual bending of electrode leads, leading to inefficient welding performance due to uneven heat distribution and lack of close attachment to bus bars, which complicates automation.
Innovation Solution
A battery module design featuring a bus bar with a base member and rotating members that press electrode leads without bending, allowing for ultrasonic and laser welding to ensure close electrical connection and uniform heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent to contact the bus bar surface, then electrical connection is achieved, but the electrode leads are not closely attached due to elastic restoration force
Solution Approach 1:
The bus bar is designed with a pressing portion that can move between a first position (not pressing) and a second position (pressing). By dynamically changing the position of the pressing portion, the electrode leads are pressed against the bus bar surface during welding to ensure close attachment, then released to allow elastic restoration without affecting connection quality.
2Reliability
If multiple electrode leads are overlapped at one point on the bus bar and welded, then electrical connection is achieved, but heat is concentrated on the uppermost electrode lead deteriorating welding performance
Solution Approach 1:
The pressing portion dynamically presses all electrode leads against the bus bar surface during welding, ensuring uniform heat distribution across all leads rather than concentrating heat on the uppermost lead. This dynamic pressing action maintains consistent contact and thermal distribution throughout the welding process.
3Ease of operation
If manual bending of electrode leads is performed, then contact with bus bar is achieved, but numerous manual works are needed reducing productivity
Solution Approach 1:
The bus bar structure includes an integrated pressing portion that automatically presses electrode leads against the bus bar surface without requiring manual bending operations. The pressing portion can be actuated automatically, eliminating the need for manual intervention and significantly improving production efficiency while maintaining ease of assembly.
4Manufacturing precision
If electrode leads are pressed during welding, then close attachment is achieved, but additional pressing mechanism complexity is introduced
Solution Approach 1:
The bus bar is segmented into a body portion and a separate pressing portion. This segmentation allows the pressing function to be integrated into the bus bar structure without significantly increasing overall complexity. The pressing portion can be independently actuated while maintaining the simplicity of the main bus bar body.
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 enables close attachment of electrode leads to bus bars without bending, improves welding performance by distributing heat evenly, and automates the production process by eliminating manual bending tasks.
Implementation Method 1
the electrode leads and the bus bar are not closely attached due to the elastic restoration force of the electrode leads 20 made of metal
Implementation Method 2
allowing for ultrasonic and laser welding to ensure close electrical connection
Implementation Method 3
allowing for ultrasonic and laser welding to ensure close electrical connection
Data Source
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AI summary
Disclosed is a battery module. The battery module includes: a battery cell stack in which a plurality of battery cells are stacked; and a bus bar to which electrode leads respectively provided at the plurality of battery cells are coupled, wherein the bus bar presses the electrode leads so that the bus bar and the electrode leads are electrically connected.