Bus Bar Hole Structure for Straight Battery Tab Assembly
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Solution Overview
Problem
Conventional battery modules require complex manufacturing processes due to the need for cutting and bending electrode tabs to connect multiple battery cells, increasing costs and complexity.
Innovation Solution
A battery module design featuring a bus bar with pre-formed holes that accommodate straight electrode tabs, allowing for simplified electrical connection through insertion and welding without deformation, reducing the number of assembly steps and maintaining a uniform connection state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional C-shaped bus bar is used to connect battery cells, then electrical connection between cells is achieved, but electrode tabs must be deformed (cut and bent) which increases the number of process operations and manufacturing complexity
Solution Approach 1:
Instead of deforming the electrode tabs to fit the C-shaped bus bar, the invention inverts the approach by making the bus bar fit around the electrode tabs. The bus bar is formed with a through-hole that receives the electrode tab, eliminating the need to deform the tabs and simplifying the assembly process.
Solution Approach 2:
The invention extracts the electrode tab from the deformation process by providing a dedicated through-hole in the bus bar specifically designed to receive the tab. This separates the connection function from the deformation operation, allowing the tab to be simply inserted and welded without cutting or bending.
2Ease of manufacture
If conventional C-shaped bus bar is used to connect battery cells, then electrical connection between cells is achieved, but the number of process operations increases which increases manufacturing cost
Solution Approach 1:
The invention inverts the conventional approach by making the bus bar accommodate the electrode tab through a through-hole, rather than deforming the tab to fit the bus bar. This simplifies the manufacturing process to basic insertion and welding operations, reducing the number of process steps and improving manufacturing efficiency.
Solution Approach 2:
The bus bar is segmented with a through-hole that separates the connection function into distinct stages: insertion of the electrode tab through the hole, followed by welding. This segmentation of the connection process eliminates complex deformation operations and reduces manufacturing complexity and cost.
3Reliability
If electrode tabs are deformed for coupling battery cells, then electrical connection is achieved, but the manufacturing process becomes more complicated
Solution Approach 1:
The invention inverts the conventional approach by making the bus bar structure adapt to the electrode tab rather than deforming the tab. The through-hole in the bus bar is specifically designed to receive and position the tab, ensuring reliable electrical connection through simple insertion and welding without complex deformation processes.
Solution Approach 2:
The through-hole in the bus bar acts as an intermediary structure that facilitates the connection between the electrode tab and the bus bar. This intermediary feature enables reliable electrical connection by providing a dedicated receptacle for the tab, eliminating the need for complex deformation operations.
4Adaptability or versatility
If conventional bus bar connection method is used, then battery cells can be connected, but deformation of electrode tabs is required which increases processing time
Solution Approach 1:
The invention inverts the conventional connection method by making the bus bar adapt to the electrode tab through a through-hole design. This allows the tab to be simply inserted and welded without time-consuming deformation operations such as cutting and bending, significantly reducing assembly time while maintaining connection versatility.
Solution Approach 2:
The through-hole in the bus bar is pre-formed to the appropriate size and shape to receive the electrode tab. This preliminary preparation of the bus bar structure eliminates the need for time-consuming deformation operations during assembly, allowing for quick insertion and welding operations.
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 simplifies the assembly process, reduces costs, and ensures a stable, visually confirmable connection between battery cells, while maintaining energy density and preventing tab deformation.
Implementation Method 1
using laser welding to secure the tabs
Implementation Method 2
ensuring uniform tab melting
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Embodiments of the present disclosure relate to a battery module. According to an embodiment of the present disclosure, there is provided a battery module including a plurality of battery cells each including at least one electrode tab, and a bus bar in contact with the electrode tabs to electrically connect the plurality of battery cells, wherein the bus bar includes a plate in which a plurality of holes are formed, and the electrode tabs are inserted into at least a portion of the plurality of holes to electrically connect the plurality of battery cells.