Busbar Welding Groove for Battery Module Laser Joining
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Solution Overview
Problem
The existing laser welding method for connecting electrode tabs in battery modules faces a reduction in welding quality when the busbar thickness is greater than the electrode tab thickness, making it difficult to apply to high-capacity batteries or those used for extended periods.
Innovation Solution
A battery module design that incorporates a busbar with a welding groove, allowing for reduced thickness at the welded portion while maintaining a larger cross-sectional area, enhancing laser welding quality and enabling application to high-capacity batteries by bending the electrode tabs and using a laser welding scheme.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar thickness is increased to maintain structural integrity for high-capacity batteries, then the reliability and load-bearing capacity improve, but the laser welding quality deteriorates due to thickness mismatch with electrode tabs
Solution Approach 1:
The busbar is designed with non-uniform thickness: the main body maintains sufficient thickness for structural integrity and high-capacity battery applications, while the welded portion features a reduced thickness (welding groove) that matches the electrode tab thickness. This local variation in geometric properties enables both structural reliability and high-quality laser welding without compromise.
2Manufacturing precision
If the busbar thickness is reduced to improve laser welding quality, then the welding precision improves, but the busbar cannot support high-capacity batteries or long-duration applications
Solution Approach 1:
The busbar incorporates a welding groove that creates a localized thinning only at the welding position, while the overall busbar thickness remains sufficient for high-capacity battery support. This allows the welded portion to achieve optimal welding quality with matched thickness to electrode tabs, while the main body retains the necessary mechanical strength and electrical conductivity for demanding applications.
3Duration of action of stationary object
If a uniform thick busbar is used to ensure durability for long-period use, then the durability and electrical conductivity improve, but the welding process becomes problematic due to thickness mismatch
Solution Approach 1:
The busbar design features a welding groove that locally reduces thickness at the connection point to match electrode tab dimensions, enabling straightforward laser welding processes. The majority of the busbar maintains its original sufficient thickness to ensure durability, electrical conductivity, and reliability for long-period battery operation, thus resolving the conflict between manufacturability and service life.
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
The solution improves welding quality and extends the applicability to high-capacity and long-duration batteries by maintaining the busbar's cross-sectional area, ensuring secure connections and efficient energy transfer.
Implementation Method 1
a busbar welding scheme allowing for a reduced thickness at a welded portion of the busbar while maintaining a total cross-sectional area of the busbar, thereby increasing a laser welding quality
Implementation Method 2
a laser welding refers to a method of irradiating a laser to one of a pair of welding targets to be welded in a state in which the welding targets face each other, and of melting a portion in which the welding targets are in contact with each other so that the welding targets are attached to each other
Data Source
AI summary
Provided is a battery module for a secondary battery. The battery module includes a busbar for a connection of electrode tabs. According to exemplary embodiments of the present disclosure, in a battery module for a secondary battery, a thickness of a welded portion may be reduced while maintaining a total cross-sectional area of a busbar when electrode tabs of each of secondary batteries are connected in series or in parallel by a laser welding. Thus, the battery module may have an enhanced welding quality, and also may have an effect of being applicable to a high-capacity battery or a battery that is used for a long period of time.