Integrated Electrode Lead Connecting Structure for Battery Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing electrode lead connecting structure in battery packs requires excessive man-hours for assembly and is prone to mistakes during the welding process, leading to potential electrical failures due to the high probability of separation of electrode busbars from sensing busbars under vehicle vibrations or impacts.
Innovation Solution
An integrated electrode lead connecting structure with L-shaped end strip busbars and middle strip busbars arranged diagonally on the printed circuit board, allowing for reduced assembly steps and minimized mistakes by ensuring proper bonding of electrode leads to sensing busbars, featuring electrode busbars integrated with L-shaped end strip busbars and middle strip busbars for stable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode busbars are separately welded to sensing busbars and electrode leads, then electrical connection is achieved, but assembly time increases and reliability decreases due to multiple welding processes
Solution Approach 1:
The patent combines the electrode busbar and sensing busbar into a single integrated busbar structure. This merging eliminates the need for separate welding processes, reducing assembly time while maintaining electrical connection reliability through a unified design that prevents separation issues
2Reliability
If electrode busbars are welded multiple times to ensure connection, then connection stability improves, but the probability of separation under vibration and impact increases
Solution Approach 1:
By integrating the electrode busbar and sensing busbar into one piece, the patent eliminates multiple welding joints that are susceptible to vibration and impact. The unified structure ensures connection stability without the harmful effects of repeated welding and potential separation
3Measurement precision
If sensing busbars are alternately arranged at opposite edges of printed circuit board, then voltage sensing is achieved, but assembly mistakes increase due to complex arrangement
Solution Approach 1:
The patent positions the integrated busbar at one end of the printed circuit board rather than alternately arranging sensing busbars at opposite edges. This asymmetric simplification maintains voltage sensing capability while dramatically reducing assembly complexity and mistakes
4Adaptability or versatility
If multiple separate components are used in electrode lead connecting structure, then functional requirements are met, but device complexity increases
Solution Approach 1:
The patent integrates multiple functional components (electrode busbar, sensing busbar) into a single unified busbar structure. This merging reduces device complexity while maintaining all necessary functional adaptability for voltage sensing and electrical connection
Solution Approach 2:
The integrated busbar performs multiple functions simultaneously - serving as both an electrode connection point and a voltage sensing point. This multi-functionality reduces the number of separate components needed while maintaining full functional capability
Data Source
AI summary
Disclosed are an electrode lead connecting structure capable of simplifying an assembly process of busbars by integrating sensing and electrode busbars, and of minimizing worker's mistakes during the assembly process by almost horizontally arranging busbars on a printed circuit board for each level, a battery module including the electrode lead connecting structure, and a battery pack including the battery module. An electrode lead connecting structure according to the present disclosure includes a printed circuit board, first and second electrode-integrated sensing busbars provided at a lowest level of one side edge of the printed circuit board and at a highest level of an opposite side edge of the printed circuit board, respectively, a first sensing busbar group located on the first L-shaped end strip busbar at the one side edge, and a second sensing busbar group located under the second L-shaped end strip busbar at the opposite side edge.