Cell Lead Support Module for Stable Battery Pack Welding
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Solution Overview
Problem
Existing battery cell lead support systems face issues with unstable support and positioning during welding, leading to increased assembly tolerance and welding defects, which incur additional costs.
Innovation Solution
A cell lead support module with a counter jig featuring both circular and trapezoid shapes to stabilize the welding surface and facilitate precise positioning, incorporating a cell lead guide portion with alternating jig receiving and guide pillars for improved assembly and reduced defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a circular counter bar is used to facilitate positioning and reduce assembly tolerance, then assembly ease is improved, but support force for cell leads deteriorates
Solution Approach 1:
The counter bar transitions from a fully circular cross-section to an asymmetric design with a circular upper portion for positioning and a trapezoidal lower portion for support. This asymmetric shape allows the upper circular part to interface with the circular hole in the bus bar for easy positioning, while the lower trapezoidal part provides enhanced contact surface with the cell lead to endure welding jig forces.
2Strength
If a trapezoid counter bar is used to secure strong support force, then support strength is improved, but position regulation deteriorates
Solution Approach 1:
The counter bar is segmented into two distinct functional portions: a upper circular portion that interfaces with the circular hole for precise positioning and assembly, and a lower trapezoidal portion that contacts the cell lead for strong support. This segmentation allows each portion to be optimized for its specific function without compromising the other.
3Manufacturing precision
If strong pressing force is applied to the seating surface for welding, then welding quality is improved, but cell lead stability deteriorates
Solution Approach 1:
The counter bar is positioned in advance to provide preliminary support to the cell lead before the welding jig applies pressing force. By having the counter bar already in place with its trapezoidal support surface, the cell lead is pre-positioned and stabilized, preventing it from being drawn into empty space when the welding jig applies strong pressing force for welding.
Data Source
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AI summary
A cell lead support module including a cell lead guide portion applied to an end of a battery pack, including an end coupled to a sensing assay, to guide a battery cell in coupling to the battery cell; and a counter jig interpolated into the cell lead guide portion to support a cell lead of the battery cell on a side of the battery cell. The counter jig includes a support portion to support the cell lead in a first end of the counter jig contacting the cell lead of the battery cell; and an aiming portion including a coupling reference point of the counter jig, in a second end of the counter jig.