Battery Module Busbar Tongs for Spring-Back-Free Lead Joining

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Solution Overview

Problem

The existing battery module connection structure between electrode leads and busbars is prone to spring-back phenomena during bending, leading to inconsistent adhesion strength and potential electrical connectivity issues.

Innovation Solution

A battery module design featuring a busbar with a tongs part and a fixing part, where electrode leads are inserted and adhered without bending, using a jig for precise contact and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode leads are bent and adhered to busbar in conventional manner, then electrical connection is established, but spring-back phenomenon occurs causing inconsistent adhesion strength and reduced reliability

Engineering Contradiction:

Improveadhesion strength consistencyVSAvoidmanual bending operation complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of bending the electrode lead to fit the busbar, the busbar is designed with a tongs part that actively grasps and holds the electrode lead in its natural straight state. This inverts the conventional approach by making the connector adapt to the lead rather than forcing the lead to adapt to the connector.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The tongs part of the busbar is designed to automatically grasp and hold the electrode lead through its elastic deformation capability. The busbar structure itself provides the clamping force needed for secure adhesion without requiring external manual intervention or additional fastening mechanisms.

Inventive Principle:

Principle #25Self-service

2Productivity

If multiple electrode leads are bent side-by-side, then connections are made, but overlapping and gaps occur reducing welding adhesion quality

Engineering Contradiction:

Improveassembly speedVSAvoidwelding adhesion uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The busbar is segmented into multiple tongs parts, each independently designed to grasp a specific electrode lead. This segmentation allows each lead to be held at the optimal position without interference from adjacent leads, ensuring uniform welding adhesion for each connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tongs parts extend in the width direction of the busbar, utilizing the lateral dimension to provide separation and positioning for multiple electrode leads. This dimensional arrangement prevents overlapping and ensures consistent spacing between connected leads.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If manual bending is performed to prevent lead damage, then lead integrity is maintained, but process automation speed decreases

Engineering Contradiction:

Improvelead integrityVSAvoidprocess automation speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The manual mechanical bending operation is replaced by the elastic mechanical action of the tongs part. The busbar's inherent elasticity provides the necessary deformation and clamping force automatically during assembly, eliminating the need for manual bending while maintaining lead integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The design changes the mechanical parameters of the busbar by incorporating elastic deformation capability in the tongs part. This allows the busbar to dynamically adjust its shape during assembly to securely hold the electrode lead without requiring manual intervention, thereby improving both reliability and automation speed.

Inventive Principle:

Principle #35Parameter changes

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 design enhances the adhesion strength between electrode leads and busbars, improves the reliability of electrical connections, and simplifies the manufacturing process by eliminating manual bending operations.

Implementation Method 1

electrode leads are subjected to laser welding or the like with the busbar mounted on the busbar frame to adhere the electrode lead to the busbar

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

there is a problem that a spring-back phenomenon may occur, whereby a previously bent electrode lead is restored to its original shape by elasticity

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12266823B2Battery module and manufacturing method thereof

Publication Date: 2025.04.01 LG ENERGY SOLUTION LTD

AI summary

The present disclosure relates to a battery module including a busbar structure for adhesion with an electrode lead. The battery module can include a battery cell stack having a plurality of stacked battery cells, electrode leads protruding from the battery cell stack, a busbar electrically connected to the electrode leads, and a busbar frame on which the busbar is mounted. The busbar can be formed of a tongs part and a fixing part for connecting and fixing the tongs part. The electrode leads can be mounted between the tongs part of the busbar. The battery module can be manufactured through the steps of mounting a busbar in an opening part of a busbar frame, inserting an electrode lead between the tongs part of the busbar, closely adhering the busbar and the electrode lead through a jig, and removing the jig.