Battery Module Busbar Slit Assembly for Stronger Tab Welding
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Solution Overview
Problem
Conventional battery modules face inefficiencies in welding electrode tabs to busbars due to reduced junction area and coupling strength, especially as battery cells become thinner, leading to potential connections during welding operations.
Innovation Solution
A battery module design featuring a bent electrode tab inserted into a busbar slit, with a welding method like laser welding to form a stable connection, allowing for improved electrical connectivity without the need for a welding jig and enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are made thinner to increase energy density, then volumetric energy density is improved, but the junction area between electrode tab and busbar is reduced leading to decreased coupling strength
Solution Approach 1:
The electrode tab is bent into a three-dimensional configuration that extends through the busbar slit, transforming the connection from a simple surface contact to a multi-dimensional embedded structure. This dimensional change increases the effective contact area and mechanical interlocking without requiring thicker battery cells.
Solution Approach 2:
The bent electrode tab is inserted into and nested within the slit of the busbar, creating a nested structure where the electrode tab fits inside the busbar's structural feature. This nesting provides mechanical support and increases coupling strength while maintaining a compact design suitable for thin battery cells.
2Reliability
If conventional welding jig is used to bring electrode tab and busbar into close contact, then welding stability is improved, but device complexity and productivity are worsened
Solution Approach 1:
The bent electrode tab structure itself provides the positioning and contact function that would otherwise require an external welding jig. The tab's geometry enables it to automatically align and maintain proper contact with the busbar during welding, making the welding process self-positioning and eliminating the need for complex positioning equipment.
Solution Approach 2:
The electrode tab is pre-bent into its final configuration before the welding operation. This preliminary shaping ensures that when the tab is inserted into the busbar slit, it is already in the correct position and orientation for welding, eliminating the need for complex real-time positioning during the welding process.
3Stability of the object's composition
If electrode tab is bent at high bending angle to fit into busbar slit, then junction stability is improved, but manufacturing complexity increases
Solution Approach 1:
The bending angle of the electrode tab is optimized to balance junction stability and manufacturability. By carefully selecting the bending angle parameter, the design achieves sufficient mechanical interlocking and electrical contact while remaining compatible with standard bending capabilities in battery manufacturing equipment.
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
Ensures reliable electrical connections between electrode tabs and busbars, simplifies the junction process, and increases the durability and productivity of battery modules by maintaining a stable connection state and improving welding quality.
Implementation Method 1
the bent portion of the electrode tab inserted into the slit and the busbar are joined to each other by a welded portion
Data Source
AI summary
Proposed are a battery module and a method of assembling the battery module. The battery module includes a plurality of battery cells each including an electrode tab; and a busbar having a plurality of slits, and electrically connecting the plurality of battery cells to each other, wherein the electrode tab is bent and is inserted into the slit, and wherein a bent portion of the electrode tab inserted into the slit and the busbar are joined to each other by a welded portion. The present disclosure may include a method of assembling a battery module using a bent electrode tab and a slit of a busbar.