Busbar With Locking Biasing Portion For Battery Welding
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Solution Overview
Problem
Conventional assembled batteries face issues with inappropriate welding of busbars and electrode terminals, leading to potential damage to single cells and connection failures due to difficulties in adjusting laser beam irradiation conditions and ensuring proper contact between welded objects.
Innovation Solution
The solution involves a busbar structure with a plate-shaped joining projection and locking biasing portions that allow for surface contact and welding of electrode terminals and busbars while enabling the verification of welding states, preventing gaps and ensuring appropriate welding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser beam output is increased to ensure welding penetration, then welding reliability improves, but single cell damage risk increases
Solution Approach 1:
The busbar serves as an intermediary element between the laser beam and the electrode terminal. By designing the busbar with specific thickness and material properties, it acts as a controlled mediator that absorbs and distributes the laser energy, preventing direct excessive heating of the electrode terminal while ensuring adequate welding penetration through proper energy transmission.
Solution Approach 2:
The invention optimizes the busbar parameters (thickness, material composition, geometric shape) to achieve the desired welding performance. By carefully selecting and adjusting these parameters, the system achieves reliable welding penetration while controlling the harmful thermal effects on the single cell components.
2Object-affected harmful factors
If laser beam output is decreased to prevent single cell damage, then single cell safety improves, but welding quality deteriorates
Solution Approach 1:
The busbar acts as a thermal buffer and energy distributor, mediating between the laser beam and the electrode terminal. This intermediary structure allows lower laser power to be used while still achieving adequate welding penetration, as the busbar's geometry and material properties facilitate controlled heat distribution.
Solution Approach 2:
The invention replaces reliance on high laser power (energy-based approach) with a mechanically optimized busbar structure (geometry-based approach). The busbar's thickness, shape, and material are designed to naturally facilitate heat distribution and welding penetration, reducing the need for high-energy laser input.
3Object-affected harmful factors
If busbar thickness is increased to prevent laser penetration through electrode terminal, then single cell protection improves, but welding penetration capability deteriorates
Solution Approach 1:
The invention optimizes the busbar thickness parameter to achieve a balanced state. The thickness is carefully selected to be sufficient to prevent laser beam penetration through to the electrode terminal (protecting the single cell) while remaining thin enough to allow adequate laser energy transmission for reliable welding. This optimal parameter value reconciles the conflicting requirements.
Solution Approach 2:
The busbar is designed with non-uniform local properties, including variations in thickness and material composition at different regions. The local geometry is optimized to control heat distribution patterns, ensuring that the laser energy is adequately absorbed and distributed for welding while preventing excessive heat concentration that could damage the single cell.
4Manufacturing precision
If busbar thickness is decreased to improve welding penetration, then welding quality improves, but laser beam penetration through busbar increases causing single cell damage
Solution Approach 1:
The busbar thickness parameter is optimized to a specific value or range that simultaneously achieves adequate welding penetration and prevents harmful laser beam transmission. This parameter optimization ensures that the busbar is thin enough to allow sufficient laser energy for welding while thick enough to block excessive energy that could damage the single cell.
Solution Approach 2:
The busbar may utilize composite material structures or material combinations with specific thermal and optical properties. These composite structures are designed to have controlled laser absorption and thermal conduction characteristics, enabling the busbar to facilitate welding penetration while blocking harmful laser transmission to the single cell.
5Ease of manufacture
If electrode terminals are brought into surface contact for welding, then welding accessibility improves, but gap formation risk increases leading to single cell damage
Solution Approach 1:
The busbar is pre-positioned and secured in place before the electrode terminals are brought into contact for welding. This preliminary positioning ensures that the electrode terminals are correctly aligned and maintained in proper contact during the welding process, preventing gap formation that could allow laser beam penetration and single cell damage.
Solution Approach 2:
The busbar serves as a stabilizing intermediary structure that maintains the positional relationship between electrode terminals during welding. By providing a rigid reference structure, the busbar helps prevent relative movement and gap formation between the electrode terminals, ensuring consistent contact and preventing harmful laser transmission.
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 approach allows for reliable welding of busbars and electrode terminals, preventing damage to single cells and connection failures, and is applicable with various welding methods, including laser and ultrasonic welding.
Implementation Method 1
a contact portion between the busbar 130 and the electrode terminal 112 is irradiated with a laser beam L from outside of the busbar 130 and a welded portion 140 is formed
Implementation Method 2
applicable with various welding methods, including laser and ultrasonic welding
Data Source
AI summary
In an assembled battery 1 disclosed herein, each of adjacent single cells 10 is electrically connected by a busbar 30. The busbar 30 of the assembled battery 1 includes a plate-shaped base portion 32 which extends along an arrangement direction X, and a joining projection 36 extending along electrode terminals 12 and 14 and a locking biasing portion 38 which locks the electrode terminals 12 and 14 and the busbar 30 to each other and which biases the electrode terminals 12 and 14 toward the joining projection 36 are formed at both ends of the base portion 32. Furthermore, in the assembled battery 1 disclosed herein, the electrode terminals 12 and 14 and the joining projection 36 come into surface contact with each other and tip portions 12a and 14a of the electrode terminals 12 and 14 and a tip portion 36a of the joining projection 36 are welded to each other. Accordingly, welding between the electrode terminals 12 and 14 and the busbar 30 can be performed in an appropriate manner.