Battery Interconnect Inlays for Vibration Welding
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Solution Overview
Problem
The efficiency, consistency, and reliability of vibration-welded connections between conductive battery tabs and interconnect members in battery modules are compromised by excessive heat dissipation, which affects the durability of the welds.
Innovation Solution
The interconnect member incorporates strategically positioned inlays and voids to reduce thermal mass, and may include insulating or heat-deterring materials to minimize heat dissipation, allowing for optimal like-material welding and retaining heat at the weld spot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the interconnect member is constructed of highly conductive material to ensure electrical performance, then electrical conductivity is improved, but heat dissipation increases causing poor weld quality
Solution Approach 1:
The interconnect member incorporates localized inlays of highly conductive material (such as copper or copper alloy) positioned precisely at the welding interface, while the bulk structure uses materials with appropriate thermal properties. This local concentration of conductive material improves weld quality and electrical performance without requiring the entire interconnect member to be highly conductive, thereby reducing overall heat dissipation.
Solution Approach 2:
The interconnect member is constructed as a composite structure combining different materials with complementary properties. The inlays use highly conductive materials for optimal welding, while the surrounding structure may use materials with lower thermal conductivity to minimize heat dissipation. This composite approach allows simultaneous optimization of weld quality and thermal management.
2Strength
If the interconnect member has sufficient thermal mass to maintain structural integrity, then structural strength is improved, but heat dissipation increases reducing weld temperature
Solution Approach 1:
The inlays are positioned locally at the welding interface where thermal mass is needed to maintain weld spot temperature, while the rest of the interconnect member maintains sufficient structural integrity with reduced thermal mass. This localized approach allows the welding interface to retain heat effectively without the entire structure requiring high thermal mass.
Solution Approach 2:
The interconnect member is segmented into functional zones: the inlay region at the welding interface that retains heat, and the bulk structure that provides structural support. This segmentation allows different parts of the same component to have different thermal mass characteristics optimized for their specific functions.
3Reliability
If like-material welding is used to improve weld reliability, then weld durability is improved, but material selection becomes constrained
Solution Approach 1:
The interconnect member uses composite construction with inlays of specific materials (such as copper, copper alloy, aluminum, or aluminum alloy) that match the battery tab materials for like-material welding, while the bulk structure can use different materials optimized for other properties. This allows like-material welding at the interface while maintaining overall design flexibility.
Solution Approach 2:
The inlays are selected to match the material of the battery tabs for optimal welding (like-material welding), while the rest of the interconnect member can use materials optimized for structural, thermal, or electrical properties. This local material matching ensures weld durability without constraining the overall material selection for the entire component.
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 enhances the weld quality by reducing heat loss and ensuring consistent, durable connections between battery tabs and interconnect members, suitable for high-voltage applications in hybrid and electric vehicles.
Implementation Method 1
an insulating or heat-deterring outer ring to reduce heat dissipation from a weld spot as it is being welded
Implementation Method 2
The process of vibration welding uses a sonotrode to apply calibrated oscillations or vibrations to adjacent work pieces
Implementation Method 3
The vibrations create substantial surface friction at interfacing surfaces of the work pieces. Heat resulting from the generated friction softens the interfacing surfaces
Data Source
AI summary
An interconnect member for use in a vibration welded battery module having a battery tab includes a portion weldable to the battery tab, and an inlay. The inlay is positioned with respect to the portion. The inlay may be the same material as the portion, with an insulating or heat-deterring outer ring, or may be the same material as the battery tab with or without the outer ring. Voids or openings may be provided in the interconnect member to reduce the thermal mass of the interconnect member. The voids may be defined by laminated or clad layers of the portion, and may be filled with an insulating material. A battery module is also disclosed having the battery tabs and the interconnect member noted above.