Laser Welding Jig for Busbar-Free Battery Cell Lead Joining
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Solution Overview
Problem
Existing battery cell assemblies require busbars for electrical connection, which increase weight and cost, and there is a need for a more efficient welding method that omits the use of metal busbars.
Innovation Solution
A laser welding jig and method that includes a protective jig positioned between adjacent battery cell leads, using a pallet and insulating block to stabilize and insulate the welding process, allowing for direct electrical connection without a busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are used for electrical connection of battery cells, then reliable electrical connection is achieved, but weight and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the busbar component from the battery assembly system. By directly welding leads of adjacent battery cells together, the busbar is completely removed, achieving weight reduction while maintaining electrical connection reliability through direct lead-to-lead welding joints.
Solution Approach 2:
The patent merges the functions of the busbar and lead connections by directly welding leads of adjacent battery cells together. This integration eliminates the intermediate busbar component, creating a more compact and lighter electrical connection system while maintaining reliable current flow between cells.
2Reliability
If busbars are used for electrical connection, then electrical connectivity is ensured, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the busbar component from the battery assembly system. By directly welding leads of adjacent battery cells together, the busbar is completely removed, achieving weight reduction while maintaining electrical connection reliability through direct lead-to-lead welding joints.
Solution Approach 2:
The patent replaces expensive metal busbars with a simpler, more cost-effective direct lead welding approach. The elimination of busbar materials and associated manufacturing steps significantly reduces production costs while maintaining reliable electrical connections through optimized welding processes.
3Object-affected harmful factors
If protective jig is positioned between adjacent leads, then battery cell assembly is protected from welding plasma, but device complexity increases
Solution Approach 1:
The patent introduces a protective jig as an intermediary component positioned between adjacent battery cell leads during welding. This simple protective barrier effectively shields the battery cell assembly from welding plasma damage without requiring complex shielding systems or advanced plasma control mechanisms.
Solution Approach 2:
The protective jig functions as a thin protective barrier that effectively blocks welding plasma from damaging the battery cell assembly. This simple shielding approach provides adequate protection without adding significant structural complexity or requiring厚重 protective enclosures.
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 protects the battery cell assembly from welding plasma, ensures stable electrical connections, reduces weight and cost, and prevents short circuits, enabling efficient assembly of battery packs without busbars.
Implementation Method 1
laser welding jig applied to a battery cell assembly in which adjacent two leads are bent and welded
Data Source
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AI summary
A laser welding jig according to the present invention is applied to a battery cell assembly including a plurality of stacked battery cells and a side frame covering at least a portion of the plurality of battery cells, in which two adjacent leads are bent and welded, and the laser welding jig comprises: a pallet configured to allow the battery cell assembly to be seated thereon; and a protective jig arranged between the two adjacent leads.