Busbar Support Holes to Prevent Cell Terminal Welding Lift
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Solution Overview
Problem
Poor welding between busbars and cell terminals due to glue dispensing protrusions lifting the plastic support during the sealing process of square hard-shell lithium-ion batteries, leading to product quality issues.
Innovation Solution
Designing hole bodies on the busbar assembly support to correspond to glue dispensing protrusions at liquid injection holes, preventing the protrusions from lifting the support during welding, thereby ensuring stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing is performed through steel ball hitting and glue dispensing on liquid injection holes, then sealing reliability is improved, but glue dispensing protrusions lift the plastic support causing poor welding quality
Solution Approach 1:
The patent applies preliminary anti-action by designing hole bodies in advance on the support at positions corresponding to the glue dispensing protrusions. This pre-planned structural feature prevents the protrusions from lifting the support during the welding process, thereby counteracting the harmful effect before it occurs and ensuring both sealing reliability and welding quality.
2Productivity
If the busbar assembly covers the cells for welding, then welding efficiency is improved, but the plastic support is lifted by glue dispensing protrusions causing poor welding
Solution Approach 1:
The hole bodies are pre-designed on the support at positions corresponding to the glue dispensing protrusions. This preliminary structural arrangement prevents the protrusions from lifting the support during welding, allowing the busbar assembly to cover the cells efficiently without compromising welding quality.
3Ease of manufacture
If the support structure is simplified for ease of manufacture, then manufacturing cost is reduced, but the support cannot accommodate glue dispensing protrusions without deformation
Solution Approach 1:
The support is segmented with hole bodies at specific positions corresponding to the glue dispensing protrusions. This segmentation allows the support to accommodate the protrusions without deformation while maintaining overall structural simplicity and ease of manufacture.
Solution Approach 2:
The support has local quality variations with hole bodies positioned at specific locations where glue dispensing protrusions occur. This localized structural feature maintains support stability at critical positions while keeping the overall support structure simple and easy to manufacture.
Data Source
Figure 1~2
Figure 3
AI summary
A busbar assembly, a battery module, and a battery pack are provided. The busbar assembly includes: a support, where a plurality of hollow-out structures are disposed on the support, and each hollow-out structure is configured to correspond to a terminal of at least one cell of the battery module; and a plurality of busbars, respectively mounted at the plurality of hollow-out structures, where each busbar is configured to connect to the terminal of the at least one cell; and a plurality of hole bodies are further provided on the support, and at least a part of the plurality of hole bodies are configured to respectively correspond to glue dispensing protrusions that are at liquid injection holes of a plurality of cells of the battery module. The hole bodies respectively corresponding to the glue dispensing protrusions that are at the liquid injection holes of the plurality of cells are provided on the support of the busbar assembly. In this way, when the busbars are welded to the terminals of the cells, poor welding between the busbars and the terminals of the cells caused because the glue dispensing protrusions lift the support can be avoided, thereby improving product quality and use safety performance.