Battery Module Busbar Solder Pin Connection for Reworkable Sensing

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Solution Overview

Problem

The existing connection method between bus bars and voltage sensing members in battery modules is costly, difficult to quality control, and lacks reworkability due to laser welding, leading to the need for discarding entire components if defective.

Innovation Solution

A battery module design featuring bus bars with pin holes and solder pins for the voltage sensing member, allowing easy insertion and removal without welding, enabling quick assembly and rework.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If laser welding is used to connect the sensing member to the bus bar, then the connection strength is improved, but the manufacturing cost increases and quality control becomes difficult

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost and quality control

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the laser welding process (thermal/energy-based system) with a mechanical insertion system using pins and holes. The sensing member is connected to the bus bar by inserting pins through aligned holes and securing with retainers, eliminating the need for laser welding equipment and complex quality control procedures while maintaining connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If laser welding is used to connect the sensing member to the bus bar, then the connection strength is improved, but the ease of repair deteriorates

Engineering Contradiction:

Improveconnection strengthVSAvoidreworkability

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The patent segments the connection system into separable components: the sensing member with pins, the bus bar with holes, and retainers for securing. This segmentation allows the sensing member to be independently removed and replaced without affecting the bus bar or requiring complex repair procedures, dramatically improving ease of repair while maintaining connection strength through the retainer mechanism.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the sensing member is defective, then the reliability is maintained by discarding the entire assembly, but the loss of substance increases

Engineering Contradiction:

Improvesystem reliabilityVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent extracts the sensing member as a separate, replaceable component from the bus bar assembly. When the sensing member becomes defective, only the sensing member itself needs to be removed and replaced, while the bus bar and other components remain intact and reusable. This extraction approach maintains system reliability by enabling easy replacement of defective parts while significantly reducing material waste compared to discarding the entire assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12562441B2Battery module comprising solder pin for connection to busbar and battery pack including same

Publication Date: 2026.02.24 LG ENERGY SOLUTION LTD

AI summary

A battery module, including battery cells connected in series or connected in series and in parallel, a plurality of bus bars connected to corresponding electrode leads of the battery cells, and a voltage sensing member having sensing parts respectively connected to the bus bars, each of the plurality of bus bars having a pin hole perforated therethrough in a thickness direction, and each of the sensing parts having a solder pin configured to be inserted into and released from the pin hole.