Battery Module ICB Housing Wire Fixing Recess
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Solution Overview
Problem
In existing battery modules, the connection wire between the bus bar and electrode lead often results in bad welding and damage due to being interposed between the compression jig and ICB housing during laser welding, leading to imperfect adhesion and potential electrical issues.
Innovation Solution
A battery module design featuring a wire fixing unit with a recess in the ICB housing to securely insert and fix the connection wire, preventing it from being interposed between the compression jig and the housing, and ensuring stable voltage measurement by maintaining the wire's position away from the welding area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire is allowed to pass freely near the bus bar during laser welding, then the welding process can be performed, but the wire is likely to be interposed between the compression jig and ICB housing, resulting in imperfect adhesion and bad welding
Solution Approach 1:
The wire fixing unit is configured to position and secure the wire in advance before the laser welding process begins. This preliminary positioning prevents the wire from being interposed between the compression jig and ICB housing during welding, ensuring proper adhesion without requiring complex real-time adjustments during the welding process.
Solution Approach 2:
The wire fixing unit acts as an intermediary structure between the wire and the ICB housing. It provides a dedicated positioning mechanism that mediates the spatial relationship between these components, preventing direct interference between the wire and the welding zone while maintaining electrical connectivity.
2Reliability
If the wire is positioned close to the bus bar for electrical connection, then electrical connectivity is achieved, but the wire is damaged due to compression during laser welding
Solution Approach 1:
The wire is preliminarily positioned in a safe location away from the compression zone before welding begins. The wire fixing unit secures the wire in this protected position, allowing the compression jig to apply force to the bus bar and electrode lead without damaging the wire, while electrical connectivity is maintained through the fixed position.
Solution Approach 2:
The wire fixing unit creates a localized protected zone for the wire within the ICB housing. This local structural feature provides different spatial zones: one for wire placement protected from compression, and another for the welding operation, allowing both electrical connectivity and wire integrity to be maintained simultaneously.
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 prevents wire damage and ensures stable voltage measurement by maintaining the connection wire's position within the ICB housing, thereby preventing bad welding and ensuring reliable electrical connections between the bus bar and electrode lead.
Implementation Method 1
a wire fixing unit having a wire fixing recess formed by indenting an outer surface of the ICB housing toward an inner surface of the ICB housing to be located near the inner surface of the ICB housing in comparison to the connection point, and at least a part of the connection wire is inserted into and fixed in the wire fixing recess
Implementation Method 2
an electrode lead and a bus bar are connected by means of laser welding. The laser welding is performed after the electrode lead and the bus bar are closely adhered to each other by compression using a compression jig
Data Source
AI summary
Disclosed is a battery module, including a cartridge laminate including a plurality of secondary batteries, each having an electrode lead, and a plurality of cartridges configured to respectively accommodate at least one secondary battery among the secondary batteries and stacked at multi stages; an integrated circuit board (ICB) housing having a bus bar connected to the electrode lead at a predetermined connection point and coupled to one surface of the cartridge laminate; and a sensing unit having a connection wire disposed to pass through the ICB housing and connected to the bus bar to allow voltages of the secondary batteries to be sensed, wherein the ICB housing further includes a wire fixing unit having a wire fixing recess formed by indenting an outer surface of the ICB housing toward an inner surface of the ICB housing to be located near the inner surface of the ICB housing in comparison to the connection point, and at least a part of the connection wire is inserted into and fixed in the wire fixing recess.