Welding Plate Deformation for Battery Module Connection
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Solution Overview
Problem
Existing methods for electrically connecting a battery module to another electrical device face challenges due to potential position shifts and misalignment of welding plates, leading to welding failures, especially when size tolerances and arrangement tolerances between the battery module and the electrical device cause gaps or inclinations during the welding process.
Innovation Solution
A connection structure that incorporates a welding plate with a deformation-allowing groove-shaped recessed portion on a connection bus bar, allowing elastic deformation to maintain contact with the battery module's connection electrode, even if there are shifts, and a holding member with restricting pieces to prevent peeling post-welding, ensuring a firm connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a welding plate is later attached to a connection bus bar to connect battery module and electrical device, then the connection can be established, but position shift occurs between welding face and counterpart electrode leading to welding failure
Solution Approach 1:
The welding plate is designed with a deformation-allowing portion that enables elastic deformation. This dynamic characteristic allows the welding plate to adapt to position shifts between the battery module and electrical device during assembly, maintaining contact between the welding face and counterpart electrode despite manufacturing tolerances.
Solution Approach 2:
The welding plate incorporates a groove-shaped recessed portion that changes the physical parameters of the plate structure. This recessed portion creates an elastic deformation zone that can absorb dimensional variations and position shifts, transforming the rigid structure into one that can accommodate manufacturing tolerances while maintaining welding precision.
2Manufacturing precision
If the welding face is held using a jig during laser welding, then welding position can be controlled, but the welding plate cannot be properly brought into close contact with the counterpart electrode due to position shift
Solution Approach 1:
The deformation-allowing portion provides dynamic adaptability that complements the static positioning function of the jig. When the welding plate is subjected to position shifts during assembly, the elastic deformation zone absorbs these deviations, allowing the welding face to maintain close contact with the counterpart electrode even when using a jig for positioning.
Solution Approach 2:
The groove-shaped recessed portion acts as a pre-designed cushioning element that anticipates and absorbs position shifts before welding occurs. This beforehand cushioning mechanism ensures that even if the jig positioning is not perfectly accurate or if assembly tolerances exist, the welding face can still achieve proper contact with the counterpart electrode.
3Strength
If the welding plate is made rigid to maintain structural strength, then connection strength is improved, but position shifts and inclinations cannot be accommodated leading to welding failure
Solution Approach 1:
The welding plate is segmented into different functional zones: a rigid portion that provides structural strength and connection integrity, and a deformation-allowing portion with a groove-shaped recessed portion that provides adaptability to position shifts. This segmentation allows the plate to simultaneously maintain strength while accommodating assembly tolerances and position variations.
Solution Approach 2:
Different portions of the welding plate have different mechanical properties. The main body maintains rigidity for structural strength, while the groove-shaped recessed portion creates a localized zone with elastic deformation capability. This local quality differentiation allows the plate to exhibit both strength and adaptability in appropriate locations.
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 ensures a stable and conductive connection by allowing the welding plate to adjust to position shifts and maintain contact, preventing welding failures and ensuring good conductivity while restricting deformation that could lead to peeling, thus achieving a firm and reliable electrical connection.
Implementation Method 1
the deformation-allowing portion being able to elastically deform. When the welding face of the welding plate is brought into contact with the connection electrode, even if there is a shift therebetween, the welding face and the connection electrode are kept in a state of contact due to the deformation-allowing portion elastically deforming.
Implementation Method 2
the welding face of the welding plate is placed on the electrode of the battery module and is fixed by means of laser welding
Implementation Method 3
a means has been proposed in which an L-shaped welding plate with a flat welding face is later attached to a leading end of the connection bus bar by means of ultrasonic welding
Data Source
AI summary
A connection structure between a battery module and an electrical device, the connection structure for connecting a battery module in which a plurality of electric cells are arranged in a line to an electrical device arranged on a side of the battery module. The connection structure includes: a connecting portion provided in the electrical device; a connection electrode provided in the battery module; and a connection bus bar having one end and another end, the one end being connected to the connecting portion of the electrical device, and a welding plate to be welded to the connection electrode in the battery module being provided at the other end. The welding plate is provided with a deformation-allowing portion for keeping the welding plate and the connection electrode of the battery module in a state of contact, the deformation-allowing portion being able to elastically deform.