Battery Terminal Micro Weld Layout for Stable Energy Input
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Solution Overview
Problem
Existing laser welding techniques for connecting battery cell terminals are sensitive to process variations, leading to inconsistent energy input, which can result in over-penetration or inadequate joining, reducing the efficiency of power transfer.
Innovation Solution
A method involving precise control of a laser to form multiple micro welds with predetermined distances and orientations on the battery cell shoulder, forming a series of line segments with weld-free zones to ensure consistent energy application, avoiding keyhole welds and maintaining substrate integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to connect battery cells, then electrical connection is achieved, but variations in process parameters cause inconsistent energy input leading to over-penetration or inadequate joining
Solution Approach 1:
The continuous weld path is segmented into discrete weld segments separated by weld-free zones. This segmentation prevents continuous heat accumulation and allows control of energy input per segment, avoiding over-penetration while ensuring adequate joining at each segment location.
Solution Approach 2:
Weld-free zones are introduced at specific locations between weld segments to create local variations in the weld structure. These zones prevent heat buildup and allow tailored energy distribution, ensuring consistent weld quality across different regions of the battery cell connection.
2Strength
If higher laser energy is applied to ensure adequate joining, then weld strength improves, but over-penetration occurs reducing power transfer efficiency
Solution Approach 1:
Instead of applying continuous high energy that causes over-penetration, the laser energy is applied in partial, discrete segments. Each weld segment receives sufficient energy for adequate joining, while weld-free zones prevent excessive cumulative energy input that would cause over-penetration and energy loss.
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 consistency and strength of weld joints, preventing over-penetration and ensuring efficient power transfer by forming shallow, conduction welds that maintain the structural integrity of battery cell terminals.
Implementation Method 1
moving a laser to a shoulder of a battery cell and micro welding with the laser a first line segment on the shoulder of the battery cell
Implementation Method 2
forming shallow, conduction-style welds that avoid keyhole formations
Data Source
AI summary
Example illustrations are directed to methods and apparatuses comprising battery cells having weld joints. In an example method, a laser is moved to a shoulder of a battery cell. The method may further include micro welding with the laser a first line segment on the shoulder of the battery cell and moving the laser a distance on the shoulder of the battery cell. The method may also comprise micro welding with the laser a second line segment on the shoulder of the battery cell in response to moving the laser the distance. Example battery cell assemblies, e.g., for a battery pack, may have a battery cell and a weld joint on a shoulder of the battery cell. The weld joint may include a first micro weld line segment and a second micro weld line segment separated by a distance.