Patterned Bus Bar Surface for Bubble-Free Battery Lead Welding
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Solution Overview
Problem
The existing bonding between electrode leads of different metals and bus bars in battery modules is hindered by poor welding strength due to bubble formation at the interface, leading to reduced durability and increased risk of short circuits.
Innovation Solution
A bus bar with surface patterns oriented in specific directions to facilitate the discharge of air bubbles during welding, featuring slits and uneven structures that enhance bonding between electrode leads of different metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a flat bus bar is used, then the manufacturing process is simple, but the current carrying capacity is insufficient due to poor contact with battery terminals
Solution Approach 1:
The bus bar incorporates a curved surface portion that corresponds to the curved surface of the battery terminal. This curvature enables better contact between the bus bar and the battery terminal, increasing the contact area and improving current carrying capacity without requiring complex internal structures
2Quantity of substance
If the bus bar surface is made rough, then the contact area with battery terminals increases, but manufacturing precision requirements increase
Solution Approach 1:
The bus bar features a localized curved surface portion rather than a uniformly rough surface. This localized curvature provides increased contact area specifically where needed (at the battery terminal interface) while maintaining smooth surfaces elsewhere, thereby reducing overall manufacturing precision requirements
3Productivity
If a large number of bus bars are stacked, then the battery module can be assembled, but alignment precision deteriorates making assembly difficult
Solution Approach 1:
The curved surface portion of the bus bar corresponds to the curved surface of the battery terminal, creating a natural geometric fit. This equipotential geometric relationship ensures automatic alignment when bus bars are stacked, maintaining high alignment precision even with multiple pieces and simplifying assembly operations
Data Source
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AI summary
The present invention relates to a bus bar for connecting an electrode lead and a battery module comprising same. The bus bar has a surface structure having a concavity and convexity pattern aligned in one direction on a connection part with an electrode lead, and thus the weldability with the electrode lead can be enhanced.