Cell Lead Support Module With Counter Jig for Welding Precision

Solution Overview

Problem

Existing battery cell lead support systems face challenges in securing stable support and precise 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 that combines circular and trapezoid shapes, featuring a support portion and an aiming portion with a coupling reference point, facilitates stable support and precise positioning, reducing assembly tolerance and welding defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a circular counter bar is used, then position regulation is favorable and assembly tolerance is reduced, but support force is insufficient

Engineering Contradiction:

Improveassembly toleranceVSAvoidsupport force

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent merges the advantages of both circular and trapezoidal counter bars by integrating a circular portion (for position regulation and low assembly tolerance) and a trapezoidal portion (for strong support force) into a single counter bar structure. This combined geometry allows the counter bar to simultaneously achieve precise positioning and sufficient support during welding operations.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If a trapezoid counter bar is used, then support force is strong and stable, but position regulation is difficult and assembly tolerance increases

Engineering Contradiction:

Improvesupport forceVSAvoidassembly tolerance

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent merges the advantages of both circular and trapezoidal counter bars by integrating a circular portion (for position regulation and low assembly tolerance) and a trapezoidal portion (for strong support force) into a single counter bar structure. This combined geometry allows the counter bar to simultaneously achieve precise positioning and sufficient support during welding operations.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If strong pressing force is applied by welding jig, then welding quality is improved, but cell leads are drawn into empty space causing defects

Engineering Contradiction:

Improvewelding qualityVSAvoidlead displacement

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The counter bar is positioned in advance to provide preliminary support against the cell leads before the welding jig applies pressing force. This preliminary anti-action prevents the leads from being drawn into empty space during welding, eliminating the need to reduce pressing force and maintaining welding quality.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The counter bar acts as an intermediary support structure between the welding jig and the cell leads. It provides a stable reference surface that mediates the interaction between the pressing force and the leads, preventing direct displacement of the leads into empty space while still allowing effective welding pressure to be applied.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20260018746A1Cell lead support module

Publication Date: 2026.01.15 HYUNDAI MOBIS CO LTD

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.