Laser Welded Temperature Sensor Attachment on Battery Busbar

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Solution Overview

Problem

Existing methods for attaching a temperature detecting member to a busbar in power storage modules for electric and hybrid vehicles require a large number of components and complex fastening systems, which can increase the risk of overheating and reduce module lifespan.

Innovation Solution

A structure and method that uses laser welding to attach a plate-like temperature detecting member to a busbar, eliminating the need for additional fastening members by overlapping and laser-welding the attachment portion in areas not connected to electrode terminals, thereby simplifying the connection process and reducing component count.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a temperature detecting member is attached to a busbar using conventional fastening methods (bolts, nuts, or dedicated fastening members), then the temperature sensor can be securely fixed to the busbar, but the number of components increases and the device complexity increases

Engineering Contradiction:

Improvesecure attachment of temperature sensorVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The busbar and the temperature detecting member are merged into a single integrated structure where the temperature detecting member is laser-welded directly to the busbar surface. This eliminates the need for separate fastening members and reduces the total component count while maintaining secure attachment and thermal connection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conventional mechanical fastening system (bolts, nuts, or dedicated fastening members) is replaced with laser welding technology. This substitution eliminates mechanical fastening components while providing secure attachment and simultaneous thermal connection for temperature detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional fastening methods are used to attach the temperature detecting member, then secure fixation is achieved, but the assembly process becomes more complex and time-consuming

Engineering Contradiction:

Improvesecure fixationVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Mechanical fastening operations are replaced with laser welding, which automates the attachment process. The laser welding facility performs both the busbar-to-electrode terminal welding and the temperature detecting member-to-busbar welding in an integrated manner, significantly simplifying the assembly process and reducing manual intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser welding facility is designed to perform multiple functions: it welds the busbar to the electrode terminals and simultaneously welds the temperature detecting member to the busbar. This multi-functionality reduces the number of separate assembly operations and simplifies the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If additional fastening members are provided to fix the temperature detecting member, then secure attachment is achieved, but the number of components increases

Engineering Contradiction:

Improvesecure attachmentVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The busbar and temperature detecting member are combined into a single welded structure, eliminating the need for additional fastening members. The laser welding process directly joins these two components, reducing the total component count in the system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The unnecessary fastening members are extracted/removed from the system. By using laser welding to directly attach the temperature detecting member to the busbar, the patent eliminates the need for bolts, nuts, or dedicated fastening members that would otherwise be required in conventional attachment methods.

Inventive Principle:

Principle #2Taking out (Extraction)

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 approach allows for a more streamlined and efficient attachment of temperature detecting members to busbars, reducing the number of components needed and simplifying the assembly process while maintaining effective thermal connection for temperature monitoring.

Implementation Method 1

The busbar is overlapped with and laser welded to the electrode terminals

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

The attachment portion is overlapped in an area of the busbar other than an area to be laser-welded to the electrode terminals and is attached to the busbar by laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS10330536B2Structure for attaching temperature detecting member to busbar, wiring module and method for manufacturing wiring module

Publication Date: 2019.06.25 AUTONETWORKS TECH LTD

AI summary

A busbar (21) is provided for electrically connecting a temperature detecting member 40 to adjacent electrode terminals (12A, 12B) of unit cells (11). The busbar (21) is overlapped with the electrode terminals (12A, 12B) of the unit cells (11). The temperature detecting member (40) includes a plate-like heat transfer plate (42) that is overlapped in an area of the busbar (21) other than an area of the busbar (21) that is to be laser-welded to the electrode terminals (12A, 12B) and is attached to the busbar (21) by laser welding.