Stepped-Thickness Connection Bar for Lower-Energy Battery Welding
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Solution Overview
Problem
Existing connection bars in battery modules, typically made of aluminum with uniform thickness, require high-energy lasers for welding, which can damage insulating plastic parts at the battery posts, leading to insulation failure.
Innovation Solution
The connection bar design includes a main body portion and a welding portion with the welding portion having a thickness less than the main body portion, allowing for reduced laser energy during welding and minimizing damage to insulating plastic parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the connection bar is increased to improve current-carrying capacity, then the current-carrying capacity is improved, but the laser energy required for welding increases, causing damage to insulating plastic parts
Solution Approach 1:
The connection bar employs different thickness values at different locations: a first thickness for the main body and a second thickness (smaller than the first) for the welding portion. This local differentiation allows the main body to maintain sufficient current-carrying capacity while the thinner welding portion reduces laser energy requirements, preventing damage to insulating plastic parts during welding.
2Strength
If high-energy lasers are used to ensure sufficient welding energy, then the welding penetration is improved, but the insulating plastic parts at the battery posts are damaged
Solution Approach 1:
The invention changes the physical parameter of the connection bar's thickness specifically at the welding portion. By reducing the thickness parameter at the welding area (second thickness smaller than first thickness), the laser energy required for welding is reduced, allowing adequate welding penetration without excessive energy that would damage the insulating plastic parts.
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 reduces laser energy requirements during welding, preventing damage to insulating plastic parts and maintaining current-carrying capacity by optimizing the connection bar structure.
Implementation Method 1
the connection bars are welded to the battery posts using laser welding
Data Source
AI summary
The application provides a connection bar, a battery module, and a battery pack. The connection bar includes a main body portion and at least one welding portion. A thickness of the welding portion is less than a thickness of the main body portion. The connection bar can alleviate the technical problem of damage to plastic parts of the battery during a laser welding process.