Battery Pack Bus Bar Weld Path for Stronger Terminal Joints
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Solution Overview
Problem
During laser welding of bus bars to battery cell terminals, there is a risk of base material penetration due to energy concentration at specific points, which can damage battery cells and reduce coupling force.
Innovation Solution
A battery pack design with a welding portion that includes a region where the laser welding line proceeds in a direction opposite to the extension of the welding portion, and an overlap avoidance region to prevent repeated energy application at the same point, maximizing coupling force and preventing base material penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the laser welding line is formed over a wide area to maximize coupling force, then the coupling force between bus bar and battery cell terminals is improved, but the base material may penetrate due to energy concentration at specific points
Solution Approach 1:
The welding line is divided into multiple segments with different welding parameters. The welding line includes a first welding line portion with first welding parameters and a second welding line portion with second welding parameters, creating distinct welding zones that distribute energy more evenly across the welding area
Solution Approach 2:
Different regions of the welding line are assigned different welding parameters tailored to local requirements. The first welding line portion uses parameters optimized for its specific location, while the second welding line portion uses different parameters suited to its local conditions, preventing energy concentration at any single point
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 coupling force between components during laser welding while preventing base material penetration, ensuring the integrity and efficiency of the battery pack.
Implementation Method 1
after the bus bars are respectively positioned on the positive electrode terminal and the negative electrode terminal of the battery cell, the components may be coupled to each other through laser welding
Data Source
AI summary
A battery pack includes a plurality of battery cells; a housing accommodating the plurality of battery cells; a plurality of bus bars electrically connecting the plurality of battery cells; and a first welding portion for coupling a first electrode terminal provided in each of the plurality of battery cells to the bus bar and a second welding portion for coupling a second electrode terminal provided in each of the plurality of battery cells to the bus bar. At least one of the first welding portion and the second welding portion includes a region in which a laser welding line formed on the bus bar proceeds in a direction opposite to an extension direction of the welding portion.