Busbar Connection Layout for Uniform Battery Module Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of inefficient resistance welding and poor bonding reliability in battery modules due to narrow welding spaces and uneven current paths leading to welding defects and increased manufacturing costs.
Innovation Solution
A battery module design with a bus bar featuring three connection portions protruding from a metal plate, each with a welding point, ensuring equal path lengths for uniform welding and improved bonding reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welding points are added to the bus bar to increase bonding strength, then bonding reliability improves, but welding space requirements increase and welding uniformity deteriorates due to uneven current paths
Solution Approach 1:
The connection portion is divided into multiple connection portions (first, second, third connection portions) that protrude in different directions from the end of the bus bar body. Each connection portion has its own welding point, allowing distributed welding throughout the available space rather than concentrating multiple welds in a single location, thus improving bonding reliability without requiring excessive local welding space.
Solution Approach 2:
Each connection portion is positioned to contact different electrode terminals (positive or negative) of adjacent secondary batteries. The welding points are strategically located at the tips of these protruding connection portions, concentrating the welding action at optimal locations where electrical and mechanical contact is established, ensuring uniform welding quality across all joints.
2Strength
If welding points are distributed across different locations on the bus bar, then bonding strength increases, but current path length variation causes welding defects
Solution Approach 1:
The bus bar body is designed as a substantially plate-shaped component with high electrical conductivity, and the connection portions protrude perpendicularly from the same end face. This geometric configuration ensures that all welding points are at substantially equal electrical potential relative to the battery terminals, creating uniform current paths during resistance welding. The equal path lengths ensure consistent heat generation and welding quality across all bonding locations.
3Device complexity
If the bus bar uses a simple single connection design, then device complexity is reduced, but bonding strength and welding efficiency decrease
Solution Approach 1:
The connection portion is segmented into multiple protruding connection portions (first, second, third) that extend in different directions from the bus bar end. This segmentation allows simultaneous or sequential welding at multiple locations without requiring complex repositioning of welding equipment, thereby improving welding efficiency while maintaining relatively simple overall bus bar structure.
Solution Approach 2:
Instead of extending connection portions in a single linear direction, the design utilizes three-dimensional spatial arrangement with connection portions protruding in different directions (e.g., upward, sideways, downward) from the bus bar end. This multi-directional configuration maximizes the utilization of available welding space and enables efficient welding access from multiple angles, improving productivity without significantly increasing structural complexity.
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
Enhances resistance welding efficiency and bonding reliability by allowing uniform welding in narrow spaces and preventing short circuits, reducing defects and manufacturing costs.
Implementation Method 1
a bus bar including a body portion having a metal plate configured to electrically connect the plurality of secondary batteries to each other and a connection portion extending from the body portion to contact the electrode terminal
Implementation Method 2
improved in efficiency of resistance welding and bonding reliability
Data Source
AI summary
Disclosed is a battery module improved in efficiency of resistance welding and bonding reliability. The battery module includes a plurality of secondary batteries, each having electrode terminals; a module housing having an inner space configured to accommodate the plurality of secondary batteries; and a bus bar including a body portion having a metal plate configured to electrically connect the plurality of secondary batteries to each other and a connection portion extending from the body portion to contact the electrode terminal. Each of the first connection portion, the second connection portion, and the third connection portion has at least one welding point.